Air filter arrangement; assembly; and, methods

ABSTRACT

Air cleaner assemblies and components therefor are described. An example first or main filter cartridge is described which includes a media pack comprising strips of fluted material secured to facing sheets, oriented in a stack. The media pack defines opposite inlet and outlet flow faces, with flutes extending in a direction therebetween. The media pack is non-removably secured within a filter cartridge housing, at a location between opposite sections of a shell, typically secured thereto with an adhesive. The shell also defines a closed end, spaced from, but in overlap with, the outlet end face of the media pack. The closed end is typically curved and the shell typically provides either a d/b-shape or a u-shape.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of U.S. Ser. No.12/291,893, filed Nov. 14, 2008, which has now issued as U.S. Pat. No.8,216,334. The present application also includes the disclosure of, withedits, U.S. provisional application 61/003,215, filed Nov. 15, 2007 and61/130,790, filed Jun. 2, 2008 A claim of priority is made to each ofU.S. Ser. No. 12/291,893; U.S. 61/003,215; and, U.S. 61/130,790 to theextent appropriate. Also, the complete disclosures of U.S. Ser. No.12/291,893; U.S. 61/003,213; and, U.S. 61/130,790 are incorporatedherein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to filter arrangements for use infiltering air. The disclosure particularly relates to filter arrangementwith media packs that use z-filter media as characterized herein. Morespecifically, the disclosure relates to such media packs and theirinclusion in serviceable air filter cartridge arrangements, typicallyfor use in air cleaners (air cleaner assemblies). Air cleanerarrangements and methods of assembly and use are also described.

BACKGROUND

Air streams can carry contaminant material therein. In many instances,it is desired to filter some or all of the contaminant material from theair stream. For example, air flow streams to engines (for examplecombustion air) for motorized vehicles or for power generationequipment, gas streams to gas turbine systems and air streams to variouscombustion furnaces, carry particulate contaminant therein that shouldbe filtered. It is preferred for such systems, that selected contaminantmaterial be removed from (or have its level reduced in) the air. Avariety of air filter arrangements have been developed for contaminantcollection. Improvements are sought.

SUMMARY

According to the present disclosure, air cleaner assemblies(arrangements) and components therefor are described. As an example, afirst air filter cartridge, usable as a service component in the aircleaner assembly, is described. The first air filter cartridge generallycomprises a media pack positioned in a filter cartridge housing;typically the media pack is non-removably positioned in the filtercartridge housing.

The media pack is typically a z-filter media pack and has an inlet flowface and an opposite outlet flow face. The media pack is positioned in ashell or shell member of the filter cartridge housing with the outletflow face directed toward a closed end of the shell; the shell havingfirst and second side sections and a closed end section. The exampleshells depicted, have either a d/b-shape or a u-shape. In either case,the shell typically has open sides, closed in the filter cartridgehousing by a opposite first and second end members.

The first end member is positioned over a first side of the media packand shell. The first end member generally: includes a air flow outletarrangement therethrough, in flow communication with a clean air volumedefined between the closed end of the shell and the outlet flow face ofthe media pack; and, closes a first side of the media pack.

The second end member is positioned opposite the first end member, andcloses a second side of the shell and the media pack, opposite the firstside. The second end member is typically closed to passage of airtherethrough.

The resulting filter cartridge can be provided with a housing sealarrangement around the air flow outlet arrangement. In an example, thehousing seal arrangement comprises a radial seal arrangementmolded-in-place as part of the first embodiment; a specific examplebeing an inwardly directed radial seal arrangement, althoughalternatives are possible.

Also, in certain described embodiments, the second member includes aperipheral housing seal member thereon, oriented to engage, and seal to,an interior side wall of an air cleaner housing.

An air cleaner assembly is configured to operably receive the filtercartridge therein. An example air cleaner housing includes an inletarrangement (or inlet), a housing body, and an air flow outletarrangement (or outlet) oriented through the housing in a direction ofair flow generally orthogonal to an air flow direction into the inletend. The housing can include a flange around the outlet arrangementthrough the housing. The flange can be positioned for sealing engagementwith a housing seal arrangement on the filter cartridge, oriented inassociation with an air flow outlet of the filter cartridge.

An optional secondary or safety filter cartridge can be positionedsealed to the housing, and projecting into the clean air volume of thefirst filter cartridge.

In an improved arrangement as characterized herein, the shell closed endsection includes a drain aperture arrangement therein, to allow fordrainage of water from a downstream end of the filter cartridge. In anexample embodiment, interiorly of the shell, filter media is positionedover the aperture arrangement, since the aperture arrangement is throughthe shell at the clean air side of the filter cartridge. Thus, thefilter media closes the shell at this location.

A variety of specific features are described and shown.

It is noted that there is no requirement that the assembly or componentsinclude all of the individual features characterized herein, in order toobtain some advantage according to the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

Drawings from U.S. 61/003,215, filed Nov. 15, 2007

FIG. 1 is a fragmentary, schematic, perspective view of example z-filtermedia useable in arrangements according to U.S. 61/003,215.

FIG. 2 is an enlarged, schematic, cross-sectional view of a portion ofthe media depicted in FIG. 1.

FIG. 3 includes schematic views of examples of various corrugated mediadefinitions.

FIG. 4 is a schematic view of a process for manufacturing mediaaccording to the present disclosure.

FIG. 5 is a schematic cross-sectional view of an optional end dart formedia flutes useable in arrangements described herein.

FIG. 6 is a schematic depiction of a step of creating a stacked z-filtermedia pack.

FIG. 7 is a schematic side elevational view of an air cleaner assemblyincluding features according to the present disclosure.

FIG. 8 is a schematic bottom plan view of the air cleaner assembly ofFIG. 7.

FIG. 9 is a schematic outlet and elevational view of the air cleanerassembly of FIG. 7.

FIG. 10 is a schematic access end elevational view of the air cleanerassembly of FIG. 7; the view of FIG. 10 being toward an opposite endfrom that of FIG. 9.

FIG. 11 is a schematic top plan view of the air cleaner assembly of FIG.7.

FIG. 12 is a schematic cross-sectional view taken along line 12-12, ofFIG. 8.

FIG. 12A is a schematic cross-sectional view taken generally along line12A-12A, of FIG. 12.

FIG. 13 is a schematic exploded perspective view of the air cleanerassembly of FIG. 7, taken as a cross-section analogous to FIG. 12.

FIG. 14 is a schematic side elevational view of a filter cartridgecomponent of the assembly of FIGS. 7-13.

FIG. 15 is a schematic bottom plan view of the filter cartridge of FIG.14.

FIG. 16 is a schematic top plan view of the filter cartridge of FIG. 14.

FIG. 17 is a schematic outlet end elevational view of the filtercartridge of FIG. 14.

FIG. 18 is a schematic end elevational view taken toward an opposite endof the cartridge of FIG. 14, from the view of FIG. 17.

FIG. 19 is a schematic cross-sectional view to the filter cartridge ofFIG. 14, taken in the general orientation corresponding to thecross-sectional view of FIG. 12 and generally along line 19-19, FIG. 15.

FIG. 20 is a schematic cross-sectional view taken generally along line20-20, of FIG. 19.

FIG. 21 is a schematic side elevational view of a safety or secondaryfilter cartridge usable in the air cleaner assembly of FIGS. 7-13.

FIG. 22 is a schematic, top, outlet end perspective view of a secondembodiment of an air cleaner assembly according to U.S. 61/003,215.

FIG. 23 is a schematic, top, access cover end perspective view of theair cleaner assembly of FIG. 22.

FIG. 24 is a schematic, bottom, outlet end perspective view of the aircleaner assembly of FIG. 22.

FIG. 25 is a schematic, exploded, top, access cover perspective view ofthe air cleaner assembly of FIG. 22.

FIG. 26 is a schematic, exploded, top, outlet end perspective view ofthe air cleaner assembly of FIG. 22.

FIG. 27 is a schematic, top, closed end perspective view of a filtercartridge usable in the air cleaner assembly of FIGS. 22-26.

FIG. 28 is a schematic, top, outlet end perspective view of the filtercartridge of FIG. 27.

FIG. 29 is a schematic outlet end elevational view of the filtercartridge of FIGS. 27-28.

FIG. 30 is a schematic side elevational view of the filter cartridge ofFIGS. 27-28, with phantom lines indicating some internal detail.

FIG. 31 schematic is a closed end elevational view of the filtercartridge of FIGS. 27-30, with phantom lines generally indicatinginternal detail.

New Drawings Added to Previous U.S. 61/003,215

FIG. 32 is a schematic access end elevational view of a third embodimentof an air cleaner assembly according to the present disclosure.

FIG. 33 is a schematic outlet end elevational view of the air cleanerassembly of FIG. 32.

FIG. 34 is a schematic side elevational view of the air cleaner assemblyof FIGS. 32 and 33, with portions broken away to show internal detail.

FIG. 35 is a schematic top access end plan view of the air cleanerassembly of FIGS. 32-34.

FIG. 36 is a schematic bottom end plan view of the air cleaner assemblyof FIGS. 32-35.

FIG. 37 is a second side elevational view corresponding to FIG. 34.

FIG. 38 is a schematic top end perspective view of an air cleanerassembly according to FIGS. 32-37.

FIG. 39 is a schematic, exploded perspective view of the air cleanerassembly of FIG. 38.

FIG. 40 is schematic cross-sectional view of the air cleaner assembly ofFIGS. 32-39.

FIG. 41 is a schematic cross-sectional view taken generally along line41-41, FIG. 40; in FIG. 41, a cross-sectional line 40-40, indicating theview of FIG. 40.

FIG. 42 is a schematic closed end elevational view of the filtercartridge usable in the air cleaner assembly of FIGS. 32-41.

FIG. 43 is a schematic open end elevational view of the cartridge ofFIG. 42; FIG. 43 being directed toward an opposite end to that of FIG.42.

FIG. 44 is schematic top plan view of the filter cartridge of FIGS. 42and 43.

FIG. 45 is a schematic bottom plan view of the filter cartridge of FIGS.42-44.

FIG. 46 is a schematic side elevational view of the filter cartridge ofFIGS. 42-45.

FIG. 47 is a second schematic side elevational view of the filtercartridge of FIG. 46, directed toward an opposite side from the view ofFIG. 46.

FIG. 48A is a schematic cross-sectional view of the filter cartridgedepicted in FIGS. 42-47.

FIG. 48B is a schematic enlarged fragmentary view of a selected portionof FIG. 48A.

FIG. 49 is a schematic cross-sectional view taken generally along line49-49, FIG. 48.

FIG. 50 is a schematic open end elevational view of the filter cartridgeof FIG. 46, line 48A-48A indicating the cross-sectional view of FIG.48A.

FIG. 51 is a schematic top perspective view of the filter cartridge ofFIGS. 42-47; FIG. 51 being generally directed toward an closed end ofthe filter cartridge.

FIG. 52 is a schematic top perspective view of the filter cartridge ofFIG. 51, the view of FIG. 52 being directed toward an outlet end.

FIG. 53 is a schematic enlarged fragmentary view of the selected portionof FIG. 52.

FIG. 54 is a schematic exploded view of the filter cartridge of FIG. 52;in FIG. 54 a perspective view is provided generally from the sameorientation as FIG. 52.

FIG. 55 is a schematic end elevational view of a shell component of FIG.54.

FIG. 56 is a schematic side elevational view of the shell component ofFIG. 55.

FIG. 57 is a schematic perspective view a pre-form, end cover, componentof FIG. 54.

FIG. 58 is a schematic inside perspective view of the end covercomponent of FIG. 57.

FIG. 59 is a schematic outside plan view of the end cover component ofFIG. 57.

FIG. 60 is a schematic cross-sectional view taken generally along line60-60, FIG. 59.

FIG. 61 is a schematic perspective view of a seal support ring componentof FIG. 54.

FIG. 62 is a schematic plan view of the component of FIG. 61.

FIG. 63 is a schematic side elevational view of the component of FIG.62.

FIG. 64 is a schematic perspective view of a safety secondary filtercartridge of the air cleaner assembly of FIGS. 32-39.

FIG. 65 is a side elevational view of the secondary filter cartridge ofFIG. 64, with portions shown in cross-section.

DETAILED DESCRIPTION I. Z-Filter Media Configurations, Generally

Fluted filter media can be used to provide fluid filter constructions ina variety of manners. One well known manner is characterized herein as az-filter construction. The term “z-filter construction” as used herein,is meant to refer to a filter construction in which individual ones ofcorrugated, folded or otherwise formed filter flutes are used to definesets of longitudinal, typically parallel, inlet and outlet filter flutesfor fluid flow through the media; the fluid flowing along the length ofthe flutes between opposite inlet and outlet flow ends (or flow faces)of the media. Some examples of z-filter media are provided or used inU.S. Pat. Nos. 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574;6,210,469; 6,190,432; 6,179,890; 6,235,195; Des. 399,944; Des. 428,128;Des. 396,098; Des. 398,046; and, Des. 437,401; each of these fifteencited references being incorporated herein by reference.

One type of z-filter media, utilizes two specific media componentsjoined together, to form the media construction. The two components are:(1) a fluted (sometimes corrugated) media sheet; and, (2) a facing mediasheet. The facing media sheet is typically non-corrugated, however itcan be corrugated, for example perpendicularly to the flute direction asdescribed in U.S. provisional 60/543,804, filed Feb. 11, 2004, andpublished as PCT WO 05/077487 on Aug. 25, 2005, incorporated herein byreference.

The fluted (sometimes corrugated) media sheet and the facing media sheettogether, are used to define media having parallel inlet and outletflutes. In some instances, the fluted sheet and facing sheet are securedtogether and are then coiled to form a z-filter media construction. Sucharrangements are described, for example, in U.S. Pat. Nos. 6,235,195 and6,179,890, each of which is incorporated herein by reference. In certainother arrangements, some non-coiled sections or strips of fluted(sometimes corrugated) media secured to facing media, are stacked on oneanother, to create a filter construction. An example of this isdescribed in FIG. 11 of U.S. Pat. No. 5,820,646, incorporated herein byreference.

Herein, strips of material comprising fluted sheet secured to corrugatedsheet, which is then assembled into stacks to form media packs, aresometimes referred to as “single facer strips”. The term “single facerstrip” and variants thereof, is meant to refer to a fact that one face,i.e., a single face of the fluted (sometimes corrugated) sheet, is facedby the facing sheet, in the strip.

The term “corrugated” used herein to refer to structure in media, ismeant to refer to a flute structure resulting from passing the mediabetween two corrugation rollers, i.e., into a nip or bite between tworollers, each of which has surface features appropriate to cause acorrugation affect in the resulting media. The term “corrugation” is notmeant to refer to flutes that are formed by techniques not involvingpassage of media into a bite between corrugation rollers. However, theterm “corrugated” is meant to apply even if the media is furthermodified or deformed after corrugation, for example by the foldingtechniques described in PCT WO 04/007054, published Jan. 22, 2004,incorporated herein by reference.

Corrugated media is a specific form of fluted media. Fluted media ismedia which has individual flutes (for example formed by corrugating orfolding) extending thereacross.

The term “z-filter media construction” and variants thereof as usedherein, without more, is meant to refer to any or all of: a web ofcorrugated or otherwise fluted media secured to (facing) media withappropriate sealing to allow for definition of inlet and outlet flutesor flow faces; or, a media pack constructed or formed from such mediainto a three dimensional network of inlet and outlet flutes; and/or, afilter cartridge or construction including such a media pack.

In FIG. 1, an example of media 1 useable in z-filter media is shown. Themedia 1 is formed from a fluted, in this instance corrugated, sheet 3and a facing sheet 4. A construction such as media 1 is deferred toherein as a single facer or single facer strip.

In general, the corrugated sheet 3, FIG. 1 is of a type generallycharacterized herein as having a regular, curved, wave pattern of flutesor corrugations 7. The term “wave pattern” in this context, is meant torefer to a flute or corrugated pattern of alternating troughs 7 b andridges 7 a. The term “regular” in this context is meant to refer to thefact that the pairs of troughs and ridges (7 b, 7 a) alternate withgenerally the same repeating corrugation (or flute) shape and size.(Also, typically in a regular configuration each trough 7 b issubstantially an inverse of each ridge 7 a.) The term “regular” is thusmeant to indicate that the corrugation (or flute) pattern comprisestroughs and ridges with each pair (comprising an adjacent trough andridge) repeating, without substantial modification in size and shape ofthe corrugations along at least 70% of the length of the flutes. Theterm “substantial” in this context, refers to a modification resultingfrom a change in the process or form used to create the corrugated orfluted sheet, as opposed to minor variations from the fact that themedia sheet 3 is flexible. With respect to the characterization of arepeating pattern, it is not meant that in any given filterconstruction, an equal number of ridges and troughs is necessarilypresent. The media 1 could be terminated, for example, between a paircomprising a ridge and a trough, or partially along a pair comprising aridge and a trough. (For example, in FIG. 1 the media 1 depicted infragmentary has eight complete ridges 7 a and seven complete troughs 7b.) Also, the opposite flute ends (ends of the troughs and ridges) mayvary from one another. Such variations in ends are disregarded in thesedefinitions, unless specifically stated. That is, variations in the endsof flutes are intended to be covered by the above definitions.

In the context of the characterization of a “curved” wave pattern ofcorrugations, the term “curved” is meant to refer to a corrugationpattern that is not the result of a folded or creased shape provided tothe media, but rather the apex 7 a of each ridge and the bottom 7 b ofeach trough is formed along a radiused curve. A typical radius for suchz-filter media would be at least 0.25 mm and typically would be not morethan 3 mm.

An additional characteristic of the particular regular, curved, wavepattern depicted in FIG. 1, for the corrugated sheet 3, is that atapproximately a midpoint 30 between each trough and each adjacent ridge,along most of the length of the flutes 7, is located a transition regionwhere the curvature inverts. For example, viewing back side or face 3 a,FIG. 1, trough 7 b is a concave region, and ridge 7 a is a convexregion. Of course when viewed toward front side or face 3 b, trough 7 bof side 3 a forms a ridge; and, ridge 7 a of face 3 a, forms a trough.(In some instances, region 30 can be a straight segment, instead of apoint, with curvature inverting at ends of the segment 30.)

A characteristic of the particular regular, wave pattern fluted (in thisinstance corrugated) sheet 3 shown in FIG. 1, is that the individualcorrugations are generally straight. By “straight” in this context, itis meant that through at least 70%, typically at least 80% of the lengthbetween edges 8 and 9, the ridges 7 a and troughs 7 b do not changesubstantially in cross-section. The term “straight” in reference tocorrugation pattern shown in FIG. 1, in part distinguishes the patternfrom the tapered flutes of corrugated media described in FIG. 1 of WO97/40918 and PCT Publication WO 03/47722, published Jun. 12, 2003,incorporated herein by reference. The tapered flutes of FIG. 1 of WO97/40918, for example, would be a curved wave pattern, but not a“regular” pattern, or a pattern of straight flutes, as the terms areused herein.

Referring to the present FIG. 1 and as referenced above, the media 1 hasfirst and second opposite edges 8 and 9. When the media 1 is formed intoa media pack, in general edge 9 will form an inlet end for the mediapack and edge 8 an outlet end, although an opposite orientation ispossible.

Adjacent edge 8 is provided a sealant bead 10, sealing the corrugatedsheet 3 and the facing sheet 4 together. Bead 10 will sometimes bereferred to as a “single facer” bead, since it is a bead between thecorrugated sheet 3 and facing sheet 4, which forms the single facer ormedia strip 1. Sealant bead 10 seals closed individual flutes 11adjacent edge 8, to passage of air therefrom.

Adjacent edge 9, is provided seal bead 14. Seal bead 14 generally closesflutes 15 to passage of unfiltered fluid therein, adjacent edge 9. Bead14 would typically be applied as strips of the media 1 are secured toone another during stacking. Thus bead 14 will form a seal between aback side 17 of facing sheet 4, and side 18 of the next adjacentcorrugated sheet 3. When the media 1 is cut in strips and stacked,instead of coiled, bead 14 is referenced as a “stacking bead.” (Whenbead 14 is used in a coiled arrangement formed from media 1, notdepicted herein, it is referenced as a “winding bead.”)

At 20, FIG. 1, tack bead between the fluted sheet 3 and the facing sheet4 are shown.

Referring to FIG. 1, once the media 1 is incorporated into a media pack,for example by stacking, it can be operated as follows. First, air inthe direction of arrows 12, would enter open flutes 11 adjacent end 9.Due to the closure at end 8, by bead 10, the air would pass through themedia, for example as shown by arrows 13. It could then exit the mediapack, by passage through open ends 15 a of the flutes 15, adjacent end 8of the media pack. Of course operation could be conducted with air flowin the opposite direction.

Herein, a media pack comprising media 1 will sometimes be referred to ashaving a “straight through” flow construction, since air to be filteredenters and exits media pack via opposite flow faces.

For the particular arrangement shown herein in FIG. 1, the parallelcorrugations 7 a, 7 b are generally straight completely across themedia, from edge 8 to edge 9. Straight flutes or corrugations can bedeformed or folded at selected locations, especially at ends.Modifications at flute ends for closure are generally disregarded in theabove definitions of “regular,” “curved” and “wave pattern.”

Z-filter constructions which do not utilize straight, regular curvedwave pattern corrugation shapes are known. For example in Yamada et al.U.S. Pat. No. 5,562,825 corrugation patterns which utilize somewhatsemicircular (in cross section) inlet flutes adjacent narrow V-shaped(with curved sides) exit flutes are shown (see FIGS. 1 and 3, of U.S.Pat. No. 5,562,825). In Matsumoto, et al. U.S. Pat. No. 5,049,326circular (in cross-section) or tubular flutes defined by one sheethaving half tubes attached to another sheet having half tubes, with flatregions between the resulting parallel, straight, flutes are shown, seeFIG. 2 of Matsumoto '326. In Ishii, et al. U.S. Pat. No. 4,925,561(FIG. 1) flutes folded to have a rectangular cross section are shown, inwhich the flutes taper along their lengths. In WO 97/40918 (FIG. 1),flutes or parallel corrugations which have a curved, wave patterns (fromadjacent curved convex and concave troughs) but which taper along theirlengths (and thus are not straight) are shown. Also, in WO 97/40918flutes which have curved wave patterns, but with different sized ridgesand troughs, are shown.

In general, the filter media is a relatively flexible material,typically a non-woven fibrous material (of cellulose fibers, syntheticfibers or both) often including a resin therein, sometimes treated withadditional materials. Thus, it can be conformed or configured into thevarious corrugated patterns, without unacceptable media damage.

Also, it can be readily coiled or otherwise configured for use, againwithout unacceptable media damage. Of course, it must be of a naturesuch that it will maintain the required corrugated configuration, duringuse.

In the corrugation process, an inelastic deformation is caused to themedia. This prevents the media from returning to its original shape.However, once the tension is released the flute or corrugations willtend to spring back, recovering only a portion of the stretch andbending that has occurred. The facing media sheet is sometimes tacked tothe fluted media sheet, to inhibit this spring back in the corrugatedsheet. Such tacking is shown at 20.

Also, typically, the media contains a resin. During the corrugationprocess, the media can be heated to above the glass transition point ofthe resin. When the resin then cools, it will help to maintain thefluted shapes.

The media of the corrugated sheet 3 facing sheet 4 or both, can beprovided with a fine fiber material on one or both sides thereof, forexample in accord with U.S. Pat. No. 6,673,136, incorporated herein byreference. In some instances, when such fine fiber material is used, itmay be desirable to provide the fine fiber on the upstream side of thematerial and inside the flutes. When this occurs, air flow, duringfiltering, will typically be into the edge comprising stacking bead.

An issue with respect to z-filter constructions relates to closing ofthe individual flute ends. Although alternatives are possible, typicallya sealant or adhesive is provided, to accomplish the closure. As isapparent from the discussion above, in typical z-filter media,especially that which uses straight flutes as opposed to tapered flutesand sealant for flute seals, large sealant surface areas (and volume) atboth the upstream end and the downstream end are needed. High qualityseals at these locations are critical to proper operation of the mediastructure that results. The high sealant volume and area, creates issueswith respect to this.

Attention is now directed to FIG. 2, in which a z-filter mediaconstruction 40 utilizing a regular, curved, wave pattern corrugatedsheet 43, and a non-corrugated flat sheet 44, i.e., a single facer stripis schematically depicted. The distance D1, between points 50 and 51,defines the extension of flat media 44 in region 52 underneath a givencorrugated flute 53. The length D2 of the arcuate media for thecorrugated flute 53, over the same distance D1 is of course larger thanD1, due to the shape of the corrugated flute 53. For a typical regularshaped media used in fluted filter applications, the linear length D2 ofthe media 53 between points 50 and 51 will often be at least 1.2 timesD1. Typically, D2 would be within a range of 1.2-2.0 times D1,inclusive. One particularly convenient arrangement for air filters has aconfiguration in which D2 is about 1.25−1.35×D1. Such media has, forexample, been used commercially in Donaldson Powercore™ Z-filterarrangements. Another potentially convenient size would be one in whichD2 is about 1.4-1.6 times D1. Herein the ratio D2/D1 will sometimes becharacterized as the flute/flat ratio or media draw for the corrugatedmedia.

In the corrugated cardboard industry, various standard flutes have beendefined. For example the standard E flute, standard X flute, standard Bflute, standard C flute and standard A flute. FIG. 3, attached, incombination with Table A below provides definitions of these flutes.

Donaldson Company, Inc., (DCI) the assignee of the present disclosure,has used variations of the standard A and standard B flutes, in avariety of z-filter arrangements. These flutes are also defined in TableA and FIG. 3.

TABLE A (Flute definitions for FIG. 3) DCI A Flute: Flute/flat = 1.52:1;The Radii (R) are as follows: R1000 = .0675 inch (1.715 mm); R1001 =.0581 inch (1.476 mm); R1002 = .0575 inch (1.461 mm); R1003 = .0681 inch(1.730 mm); DCI B Flute: Flute/flat = 1.32:1; The Radii (R) are asfollows: R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm);R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm); Std. EFlute: Flute/flat = 1.24:1; The Radii (R) are as follows: R1008 = .0200inch (.508 mm); R1009 = .0300 inch (.762 mm); R1010 = .0100 inch (.254mm); R1011 = .0400 inch (1.016 mm); Std. X Flute: Flute/flat = 1.29:1;The Radii (R) are as follows: R1012 = .0250 inch (.635 mm); R1013 =.0150 inch (.381 mm); Std. B Flute: Flute/flat = 1.29:1; The Radii (R)are as follows: R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874mm); R1016 = .0310 inch (.7874 mm); Std. C Flute: Flute/flat = 1.46:1;The Radii (R) are as follows: R1017 = .0720 inch (1.829 mm); R1018 =.0620 inch (1.575 mm); Std. A Flute: Flute/flat = 1.53:1; The Radii (R)are as follows: R1019 = .0720 inch (1.829 mm); R1020 = .0620 inch (1.575mm).

Of course other, standard, flutes definitions from the corrugated boxindustry are known.

In general, standard flute configurations from the corrugated boxindustry can be used to define corrugation shapes or approximatecorrugation shapes for corrugated media. Comparisons above between theDCI A flute and DCI B flute, and the corrugation industry standard A andstandard B flutes, indicate some convenient variations.

Alternate flute definitions, such as those described in US Provisionalapplications: 60/899,311, filed Feb. 2, 2007; and, 60/937,162, filedJun. 26, 2007 can be utilized in arrangements according to the presentdisclosure. Each of these two US Provisional applications isincorporated herein, by reference.

II. Manufacture of Stacked Media Configurations Using Fluted Media,Generally

In FIG. 4, one example of a manufacturing process for making a mediastrip corresponding to strip 1, FIG. 1 is shown. In general, facingsheet 64 and the fluted (corrugated) sheet 66 having flutes 68 arebrought together to form a media web 69, with an adhesive bead locatedtherebetween at 70. The adhesive bead 70 will form a single facer bead14, FIG. 1.

The term “single facer bead” is meant to refer to a sealant beadpositioned between layers of a single facer; i.e., between the flutedsheet and facing sheet.

An optional darting process occurs at station 71 to form center dartedsection 72 located mid-web. The z-filter media or Z-media strip 74 canbe cut or slit at 75 along the bead 70 to create two pieces 76, 77 ofz-filter media 74, each of which has an edge with a strip of sealant(single facer bead) extending between the corrugating and facing sheet.Of course, if the optional darting process is used, the edge with astrip of sealant (single facer bead) would also have a set of flutesdarted at this location. The strips or pieces 76, 77 can then be cutacross, into single facer strips for stacking, as described below inconnection with FIG. 6.

Techniques for conducting a process as characterized with respect toFIG. 4 are described in PCT WO 04/007054, published Jan. 22, 2004incorporated herein by reference.

Still in reference to FIG. 4, before the z-filter media 74 is putthrough the darting station 71 the media 74 must be formed. In theschematic shown in FIG. 4, this is done by passing a flat sheet of media92 through a pair of corrugation rollers 94, 95. In the schematic shownin FIG. 4, the flat sheet of media 92 is unrolled from a roll 96, woundaround tension rollers 98, and then passed through a nip or bite 102between the corrugation rollers 94, 95. The corrugation rollers 94, 95have teeth 104 that will give the general desired shape of thecorrugations after the flat sheet 92 passes through the nip 102. Afterpassing through the nip 102, the flat sheet 92 becomes corrugated and isreferenced at 66 as the corrugated sheet. The corrugated (i.e., fluted)media sheet 66 is then secured to facing media sheet 64. (Thecorrugation process may involve heating the media, in some instances.)

Still in reference to FIG. 4, the process also shows the facing sheet 64being routed to the darting process station 71. The facing sheet 64 isdepicted as being stored on a roll 106 and then directed to thecorrugated sheet 66 to form the Z-media 74. The corrugated sheet 66 andthe facing sheet 64 are secured together by adhesive or by other means(for example by sonic welding).

Referring to FIG. 4, an adhesive line 70 is shown used to securecorrugated sheet 66 and facing sheet 64 together, as the sealant bead.Alternatively, the sealant bead for forming the facing bead could beapplied as shown as 70 a. If the sealant is applied at 70 a, it may bedesirable to put a gap in the corrugation roller 95, and possibly inboth corrugation rollers 94, 95, to accommodate the bead 70 a.

The type of corrugation provided to the corrugated media is a matter ofchoice, and will be dictated by the corrugation or corrugation teeth ofthe corrugation rollers 94, 95. One typical type of flute pattern willbe a regular, typically curved, wave pattern corrugation, of straightflutes, as defined herein above. A typical regular curved wave patternused, would be one in which the distance D2, as defined above, in acorrugated pattern is at least 1.2 times the distance D1 as definedabove. In one typical application, typically D2=1.25−1.35×D1; in anotherD2=1.4−1.6×D1. In some instances the techniques may be applied withcurved wave patterns that are not “regular,” including, for example,ones that do not use straight flutes.

As described, the process shown in FIG. 4 can be used to create thecenter darted section 72. FIG. 5 shows, in cross-section, one of theflutes 68 after darting and slitting.

A fold arrangement 118 can be seen to form a darted flute 120 with fourcreases 121 a, 121 b, 121 c, 121 d. The fold arrangement 118 includes aflat first layer or portion 122 that is secured to the facing sheet 64.A second layer or portion 124 is shown pressed against the first layeror portion 122. The second layer or portion 124 is preferably formedfrom folding opposite outer ends 126, 127 of the first layer or portion122.

Still referring to FIG. 5, two of the folds or creases 121 a, 121 b willgenerally be referred to herein as “upper, inwardly directed” folds orcreases. The term “upper” in this context is meant to indicate that thecreases lie on an upper portion of the entire fold 120, when the fold120 is viewed in the orientation of FIG. 5. The term “inwardly directed”is meant to refer to the fact that the fold line or crease line of eachcrease 121 a, 121 b, is directed toward the other.

In FIG. 5, creases 121 c, 121 d, will generally be referred to herein as“lower, outwardly directed” creases. The term “lower” in this contextrefers to the fact that the creases 121 c, 121 d are not located on thetop as are creases 121 a, 121 b, in the orientation of FIG. 5. The term“outwardly directed” is meant to indicate that the fold lines of thecreases 121 c, 121 d are directed away from one another.

The terms “upper” and “lower” as used in this context are meantspecifically to refer to the fold 120, when viewed from the orientationof FIG. 5. That is, they are not meant to be otherwise indicative ofdirection when the fold 120 is oriented in an actual product for use.

Based upon these characterizations and review of FIG. 5, it can be seenthat a an example regular fold arrangement 118 according to FIG. 5 inthis disclosure is one which includes at least two “upper, inwardlydirected, creases.” These inwardly directed creases are unique and helpprovide an overall arrangement in which the folding does not cause asignificant encroachment on adjacent flutes.

A third layer or portion 128 can also be seen pressed against the secondlayer or portion 124. The third layer or portion 128 is formed byfolding from opposite inner ends 130, 131 of the third layer 128.

Another way of viewing the fold arrangement 118 is in reference to thegeometry of alternating ridges and troughs of the corrugated sheet 66.The first layer or portion 122 is formed from an inverted ridge. Thesecond layer or portion 124 corresponds to a double peak (afterinverting the ridge) that is folded toward, and in preferredarrangements, folded against the inverted ridge.

Techniques for providing the optional dart described in connection withFIG. 5, in a preferred manner, are described in PCT WO 04/007054,incorporated herein by reference. It is noted that a variety ofalternate folded end closures in flutes can be used.

Techniques described herein are well adapted for use of media packs thatresult from arrangements that, instead of being formed by coiling, areformed from a plurality of strips of single facer.

Opposite flow ends or flow faces of the media pack can be provided witha variety of different definitions. In many arrangements, the ends aregenerally flat and perpendicular to one another.

The flute seals (single facer bead, winding bead or stacking bead) canbe formed from a variety of materials. In various ones of the cited andincorporated references, hot melt or polyurethane seals are described aspossible for various applications. These are useable for applicationsdescribed herein.

In FIG. 6, schematically there is shown a step of forming a stackedz-filter media pack from strips of z-filter media, each strip being afluted sheet secured to a facing sheet. Referring to FIG. 6, singlefacer strip 200 is being shown added to a stack 201 of strips 202analogous to strip 200. Strip 200 can be cut from either of strips 76,77, FIG. 4. At 205, FIG. 6, application of a stacking bead 206 is shown,between each layer corresponding to a strip 200, 202 at an opposite edgefrom the single facer bead or seal. (Stacking can also be done with eachlayer being added to the bottom of the stack, as opposed to the top.)

Referring to FIG. 6, each strip 200, 202 has front and rear edges 207,208 and opposite side edges 209 a, 209 b. Inlet and outlet flutes of thecorrugated sheet/facing sheet combination comprising each strip 200, 202generally extend between the front and rear edges 207, 208, and parallelto side edges 209 a, 209 b.

Still referring to FIG. 6, in the media pack 201 being formed, oppositeflow faces are indicated at 210, 211. The selection of which one offaces 210, 211 is the inlet end face and which is the outlet end face,during filtering, is a matter of choice. In some instances the stackingbead 206 is positioned adjacent the upstream or inlet face 211; inothers the opposite is true. The flow faces 210, 211, extend betweenopposite side faces 220, 221.

The stacked media pack 201 shown being formed in FIG. 6, is sometimesreferred to herein as a “blocked” stacked media pack. The term “blocked”in this context, is an indication that the arrangement is formed to arectangular block in which all faces are 90° relative to all adjoiningwall faces. Alternate configurations are possible. For example, in someinstances the stack can be created with each strip 200 being slightlyoffset from alignment with an adjacent strip, to create a parallelogramor slanted block shape, with the inlet face and outlet face parallel toone another, but not perpendicular to upper and bottom surfaces.

In some instances, media pack 201 will be referenced as having aparallelogram shape in any cross-section, meaning that any two oppositeside faces extend generally parallel to one another.

It is noted that a blocked, stacked arrangement corresponding to FIG. 6is described in the prior art of U.S. Pat. No. 5,820,646, incorporatedherein by reference. It is also noted that stacked arrangements aredescribed in U.S. Pat. Nos. 5,772,883; 5,792,247; U.S. PCT WO 04/071616,published Aug. 26, 2004; and U.S. Pat. No. 7,282,075. Each of these fourlatter references is incorporated herein by reference, in it entirety.It is noted that the stacked arrangement shown in U.S. Pat. No.7,282,075, is a slanted stacked arrangement.

III. Example Air Cleaners and Components A. A First Example Air CleanerDescribed in U.S. 61/003,215, FIGS. 7-21

Herein, in FIGS. 7-21, a first example air cleaner assembly andcomponents described herein, and in U.S. Ser. No. 61/003,215 aredepicted schematically. Referring to FIG. 7, air cleaner assembly 300 isdepicted in side elevational view. The air cleaner assembly 300 includeshousing 301 having an inlet side 302 and outlet end 303.

Positioned over inlet side 302 is precleaner arrangement 306. Theprecleaner 306 can, for example, include a plurality of preseparatortubes such as cyclonic separator tubes therein, not depicted in FIG. 7.Such a precleaner would typically have a dust flow outlet therein, whicheither allows for gravity removal of dust separated by the precleaner306, or attachment of a scavenge hose. An outlet 307 for a scavenge hoseis indicated at one optional location.

Air to be filtered generally passes into air cleaner assembly 301 byfirst passage into (optional) precleaner 306 in the direction of arrow310. After passage through the precleaner 306, the air enters the aircleaner housing 301, through inlet side 302. Within the housing 301 ispositioned an air filter cartridge including a media pack comprising astack of z-filter strips, generally in accord with previousdescriptions. That is, each strip would typically comprise a flutedsheet secured to a facing sheet, with the strips arranged in a stackhaving appropriate sealing to ensure that air passing into one flow facemust pass through the media before it passes through the opposite flowface. Principles discussed above in connection with FIGS. 1-6 can beused for this.

Referring to FIG. 7, a z-filter media pack 315 is depicted,schematically, in phantom lines positioned generally as oriented withinan interior of housing 301. The media pack 315 has an inlet flow face316 and an opposite outlet flow face 317. The media pack 315 has firstand opposite sides 318, 319, extending between flow faces 316, 317.Media pack 315, then, can comprise a stack of strips of z-filter media,with flutes extending in a direction between the inlet flow face 316 andoutlet flow face 317. As the air exits flow face 317, then, it will havebeen filtered by the z-filter media pack 315.

After exiting the media pack 315, the air, filtered, enters a portion ofclean air region 320 and eventually leaves the cleaner housing 301 viaan air cleaner housing outlet arrangement or outlet 321 at outlet end303. In some instances, an optional safety element or secondary elementis provided in region 320, through which the air must pass before itexits outlet 321. Filtered air exiting outlet 321 is generally indicatedby arrow 311.

FIG. 7, again, is generally schematic. The figure is intended to providean overall understanding of an orientation of a arrangement according tothe present disclosure.

As it will be apparent from discussions below, media pack 315 isnon-removably secured within a filter cartridge housing, discussedbelow. The air filter cartridge, comprising the combination of the mediapack 315 and an air filter cartridge housing, is a service part,removably positioned within an interior 301 i, of air cleaner housing301.

It is noted that the air cleaner 300 is depicted in FIG. 7 in a verticalorientation, with inlet side 302 directed upwardly. An air cleaner usinganalogous principles could be differently, for example it could beoriented with an inlet end 302 directed toward a side rather thanupwardly. Alternate orientations for the assembly 300 may be benefitedby alternate locations for dust exit outlet 307 from the optionalprecleaner 306.

Attention is directed to FIG. 8, a schematic, bottom plan view generallytaken toward end 312 of housing 301, FIG. 7. FIG. 8 is provided in partto orient the cross-sectional view of FIG. 12, discussed below.Referring to FIG. 8, the housing 301 can be seen to have first andsecond opposite sides 301 a, 301 b, and first and second opposite ends301 c, 301 d. As it will be apparent from discussions below, side 301 dcomprises a removable access cover, for service access to an interior301 i of housing 301.

Attention is now directed to FIG. 9. FIG. 9 is an outlet end elevationalview generally taken in the direction of outlet end 303, FIG. 7.Referring to FIG. 9, air cleaner outlet 303 is viewable. Also viewableis precleaner 306 positioned over inlet 302 of housing 301. Internallypositioned media pack 315, with inlet flow face 316 and opposite outletflow face 317 is depicted in phantom lines.

Referring still to FIG. 9, it can be seen that the example air cleanerhousing 301 generally includes first and second, opposite, side sections301 a, 301 b with portions 321, 322, respectively, extending generallyparallel to one another, in extension from inlet face 302 toward an aircleaner housing end 312 opposite inlet face 302. For the particularexample housing 301 depicted, end 312 is a curved end 325 and has alarger dimension D₁ thereacross, than a distance D₂ between oppositeside sections 321,322. In the example shown, curved end 325 ispositioned with side section 322 engaging the curved region 325generally tangentially. In the example depicted, however, side section321 does not engage curved end 325 tangentially.

Referring to FIG. 9, it will be understood that clean air region 320, isgenerally positioned within curved, closed, region 325 of housing 301.

Attention is now directed to FIG. 10. In FIG. 10, a side elevationalview is provided taken in the general direction of side 301 d, FIG. 8.Thus, the side view of FIG. 10 is an opposite side or end 301 d from theend 301 c viewable in FIG. 9. The end 301 d viewable in FIG. 10 isgenerally referred to as an access end 330. The access end 330 includesa removable air cleaner housing access cover 331 secured thereover. Anexample method of securement for the access cover would be to uselatches, indicated schematically at 333. An alternate, usable, approachto securement is discussed below in connection with the embodiment ofFIGS. 22-31.

At 335, a projection region in access cover 331, toward the viewer, isdepicted. An opposite side of projection 335 comprises a receiver regionor handle recess, for receipt therein of an optional handle portion of aserviceable filter cartridge, as discussed below.

In FIG. 11, a top plan view of air cleaner assembly 300 is depicted. Theview of FIG. 11 is generally taken toward precleaner 306. Individualcyclonic separator tubes 338 are schematically represented. Inoperation, as air enters the cyclonic tubes 338 (FIG. 11), a cyclonicflow pattern in each is generated, with some dust being separated andremoved through outlet 307. The remaining air is then directed into theair cleaner housing 301 for filtering, by passage through the media pack315, previously referenced.

Interior features of air cleaner assembly 300 can be understood byreview of FIG. 12, a cross-sectional view taken generally along line12-12, FIG. 8.

Referring to FIG. 12, it is noted that precleaner 306 is not depictedwith separator tubes 338 therein, for convenience. All that is viewablein FIG. 12 is outer shell or housing 306 a of the precleaner 306.

Still referring to FIG. 12, access cover 331 is removable from aremainder of housing 301, for service access to interior 301 i of thehousing 301. Within interior 301 i are positioned a first or main filtercartridge 340 and an optional safety or secondary filter cartridge 341.The first or main filter cartridge 340 includes an air filter cartridgehousing 342 with a media pack 315, having an inlet flow face 316 and anopposite outlet flow face 317, non-removably secured thereto. That is,the main filter cartridge 340, the media pack 315 is non-removablysecured within a filter cartridge housing 342.

Although alternatives are possible, for the example assembly depicted,the filter cartridge housing 342 includes an inlet end or face 345 inalignment with the inlet flow face 316 of the media pack 315. By “inalignment” in this context, it is meant that for the example air flowentering filter cartridge housing 342 through inlet end 345 will enterinlet flow 316 of the media pack 315, without turning.

On the other hand, for the example depicted, filter cartridge housing342 includes an outlet arrangement 346 in the housing 340, oriented suchthat air exiting the outlet flow face 317 of the cartridge 315 mustturn, generally orthogonally to flow through the filter media pack 315and thus to exit the air cleaner housing 301 though outlet 321. Thus,while the media pack 315 is “straight through”, with respect to air flowtherethrough; the filter cartridge 340 is not. Rather, in the examplefilter cartridge 340 is configured so that in passing from the inlet 345to the outlet 346, after passage through the media pack 315, the airmust turn to exit in a general direction orthogonal to flow into theinlet side 345.

Still referring to FIG. 12, in general terms, filter cartridge 340includes a housing 342 defining an interior 343 in which the media pack315 is positioned. More specifically, the example filter cartridgehousing 342 is defined by a shell member 344 and first and second,opposite, side members 350, 351, respectively. The media pack 315 isnon-removably secured within the shell member 344, and thus the filtercartridge housing 342, for example with an adhesive or sealant. The endmembers 350, 351, as discussed below, are mounted on opposite sides 318,319 of the media pack 315, sealing and closing the sides 318, 319; and,also, are mounted over opposite sides or ends of the shell 344, asdiscussed below.

Attention is directed to side member 350. Side member 350 includes afirst section 352 which includes a side 318 of the media pack 315 sealedthereby. Side member 350 further includes a section 355 having air flowoutlet arrangement (aperture) 346 therein, for outlet flow from thecartridge 340. This is described, further, below, in connection withother figures.

End member 351 includes a section 362 which generally encloses: a side319 of the media pack 315 opposite the side 318; and, a side of shellmember 344. Projection 363, in end member 351 projects in a directionopposite end member 350 comprises an optional handle member, formanipulating cartridge 340. The handle member 363 can have a variety ofshapes, and may in some instances include an aperture therethrough or anundercut, to facilitate gripping. For the particular example cartridge340 depicted, handle 363 is a projection with no apertures therethroughand no undercuts therein.

Still referring to FIG. 12, side member 351 further includes peripheralportion or perimeter 364 discussed further below. Extending acrossregion 365, and thus closing side member 351 is provided a projectionarrangement 366. The projection arrangement 366 includes a portion 366b, closed by end 366 e, projecting into interior cartridge 340, asdiscussed below. The projection arrangement 366 comprises a secondaryfilter cartridge support, oriented to engage and support an end ofoptional secondary cartridge 341, as discussed below. The exampleprojection arrangement 366 depicted, includes an axially, outwardly,projecting central receiving access 367 therein, projecting generallyaway from outlet arrangement 346.

The projection 366 can comprise a preformed member, secured within sidemember 351, when a remainder of side member 351 is molded or formed, forexample, when member 351 is molded-in-place. This too is discussedfurther below.

Referring to FIG. 12, downstream from first air filter cartridge 340 isprovided optional secondary cartridge 341 including media 371, in theexample surrounding an open filter interior 372. In general terms, thesecondary or safety cartridge 341 is positioned over outlet 321 so thatair exiting outlet flow face 317 of the media pack 315 must pass throughthe media 371 of the optional safety filter 341, before the air can exitoutlet aperture 321.

For the particular example arrangement depicted, secondary or safetyfilter 341 has first, open, end 341 b; and, second, closed, end 341 a.The open end 341 b allows for flow of filtered air from the secondary orsafety cartridge 341, outwardly through air flow exit 321 in the aircleaner housing 301. The second closed end 341 a generally does notpermit passage of air therethrough.

For the particular example secondary or safety filter cartridge 341depicted, the media 371 is provided in a generally conical shapetapering downwardly in extension from end 341 b to end 341 a. At theopen end 341 b, is positioned a seal arrangement 375, discussed below.The seal arrangement 375 is oriented to form a seal directed against aportion of housing 301. At end 341 a, secondary filter cartridge 341includes end cap 376 with an outward, axial, projection 377 therein,which is received, in a mating and supporting manner, within recess 367.Herein, the term “axial” when used in connection with projection 377, isgenerally meant to refer to a projection 377 oriented generally alignedwith a central axis M through the secondary filter cartridge 341. Theterm “outward” in connection with the axial projection, is meant torefer to a direction of projection generally away from end member 341 b.

Still referring to FIG. 12, air cleaner housing 301 includes inwardlydirected flange 470. Flange 470 includes an outer surface 470 o and ainner surface 470 i. For the particular assembly 300 depicted in FIG.12, seal member 346 of the filter cartridge housing 342 is configured toengage and seal to outer surface 470 o of housing flange 470. Also, sealmember 375, on secondary or safety filter cartridge 341, is configuredto engage and seal against inner surface 470 i of flange 470. Ingeneral, flange 470 can be characterized as sealing flange surroundingoutlet 321.

Attention is now directed to FIG. 12A, a schematic, cross-sectional viewtaken along line 12A-12A, FIG. 12. Referring to FIG. 12A, with respectto precleaner 306, internal cyclonic separator tubes are not depicted,but rather merely outer shell 306 a is depicted. Cartridge 340 ispositioned with inlet flow face 345 directed upwardly. Also, media pack315 is oriented with inlet face 316 directed upwardly, corresponding to(i.e. alignment with) inlet end 345 of cartridge 340. Outlet face 317 ofthe media pack 320 is shown directed downwardly, i.e. in a directionopposite inlet flow face 316. However, air filter cartridge 340, asdiscussed previously, does not include an outlet end opposite inlet end345. Rather, the outlet arrangement for filter cartridge 340, asindicated in FIG. 12 at 346, is a side outlet, and not an outlet in adirection opposite the inlet 345.

Attention is now directed to FIG. 13, an exploded, schematic view ofassembly 300. Here, cartridge 340 including media pack 315 is shownseparated from interior 301 i of housing 300, with safety cartridge 341retained in place. Referring to cartridge 340, in can be seen that thecartridge inlet flow end 345 and the media pack inlet flow face 316 aregenerally aligned, in overlap. However, outlet flow face 317 of themedia pack 320 is not aligned in overlap with outlet 346 from thecartridge 340. That is, the inlet 345 of the cartridge 340 does not facethe outlet 346, in alignment. Rather, the cartridge 340 includes aninternal clean air volume 380 therein. The clean air volume 380 is sizedto receive, projecting therein, media pack 371 of secondary filtercartridge 341, during installation.

In general terms, and still referring to FIG. 13, the air filtercartridge 340 comprises an air filter cartridge housing 342 with a mediapack 315 non-removably secured therein, as previously characterized.Cartridge 340 is further configured to define clean air volume 380adjacent the outlet flow face 317 of the media pack 320. The space 380is defined, generally, between the media pack outlet flow face 317 andclosed end 344 of shell 342. The space 380 occupies a portion of region320, FIG. 7, when the cartridge 340 is in installed.

Opposite closed end 344, the shell 342 defines open end 345.

Referring to FIG. 13, it can be seen that air which enters flow face 316(i.e. inlet face 345 of cartridge 340) is filtered by the media pack315, and exits face 317. The air is then directed by shell 342 to outlet346. When the cartridge 340 is installed within the housing 301, theoutlet 346 is aligned with outlet 321, for air flow passage from the aircleaner assembly 300. Region 380 within shell 342 is sized sufficientlylarge to receive the optional safety element 341 therein, when used.

Still referring to FIG. 13, it is noted that end member 351 definesperimeter seal member 364. The perimeter seal member 364 is sized toseal against end region 301 x of housing interior 301 i, adjacenthousing service access opening 301 y, when the cartridge 340 is operablyinstalled. Compression against surface 301 x by housing peripheralperimeter seal 364, to accomplish sealing, is provided when access cover331 is pressed against end member 351 in the general direction of arrow420, FIG. 13. That is, as perimeter flange 331 x on the access cover 331presses against end 364 x of region 364, member 364 is pressed inwardly,and expands or bulges radially outwardly, in the direction of arrow 421.This will be sufficient to form the seal at region 301 x, as described.

Attention is now directed to FIG. 14. FIG. 14 is a view of cartridge340, the orientation being generally analogous to the orientation of thehousing 301, FIG. 7. Thus, inlet flow end 345 is shown, with arrow 310indicating inlet flow. Interiorly received media pack 315 is depicted inphantom lines. Downstream clean air region 380 is depicted interiorly ofthe filter cartridge housing 342. Exit air flow from the filtercartridge 340, and thus filter cartridge housing 342, is indicatedgenerally at 311.

The cartridge 340 is a service part or replacement part. That is, whenthe air cleaner 300 is used, in due course media pack 315 will becomesufficiently loaded with dust to warrant refurbishment or replacement.This is done by replacing the entire cartridge 340, for the exampleshown.

Still referring to FIG. 14, the cartridge 340 comprises filter cartridgehousing 342 defined by shell member 344 and first and second end members350, 351.

The shell 344 generally wraps around portion of media pack 315 andregion 380, but does not extend across inlet end 345, in the viewdepicted. Thus, the shell 344 includes closed end section 344 aextending across, and spaced from, outlet end 317 of the media pack 315.The shell 344 further includes a first side 415 toward the viewer inFIG. 14, and an opposite second side section 416 away from the viewer inFIG. 14. The opposite side section 416 is viewable in FIG. 15.

Referring to FIG. 15, the view is taken toward closed end section 344 aof shell 344. Here, opposite sides 415, 416 are indicated.

Attention is now directed to FIG. 16, a top plan view of cartridge 340.Here, the media pack 315 is viewable, exposed an inlet end 345 of thecartridge 340. Thus, in FIG. 16, inlet end 316 of the media pack 315 isviewable. The depiction is schematic, and there is no specific effortmade to depict individual inlet flutes and outlet flutes of the mediapack 320.

It is noted that the cartridge 340 may include a screen extending acrosscartridge face 345, and media pack face 316; a screen being representedby phantom lines 430. Further, or alternatively, a grid arrangement orother arrangement can be provided at this location.

Still referring to FIG. 16, opposite end members 350, 351 are viewable.It is noted that shell side 416 includes an outer or bottom, projectionsection 416 x therein, discussed below.

The media pack 315 will typically be secured to opposite end edges 415y, 416 y, of shell 344, along regions 440, 441 by an adhesive, forexample a hot melt sealant or other sealant material. This would ensureagainst leakage of unfiltered air between the media pack 315 and theshell member 344.

Attention is now directed to FIG. 17. FIG. 17 is a elevational view offirst or main filter cartridge 340 taken generally toward end member350. The view is generally through outlet aperture 345, to region 380.At 366 a, the inner, closed surface of projection 366, FIG. 12, isshown. At 367, the axially, outwardly, projecting recess, FIG. 12, isshown.

The media pack is indicated in FIG. 17 at 315, by phantom lines. Withrespect to the view of FIG. 17, air to be filtered would generally enterthe cartridge 340 with the direction of arrow 310 and would exit thecartridge through aperture 316, toward the viewer.

Attention is now directed to FIG. 18, a side elevational view ofcartridge 340, taken generally toward end member 351. Perimeter sealmember 364 is shown extending completely around a perimeter of endmember 351. Handle 363 is viewable, projecting toward the viewer. At366, the secondary filter cartridge support is viewable, with recess 367projecting toward the viewer.

Referring to each of FIGS. 17 and 18, it can be seen that from the side,or in cross-section, the cartridge 340, in particular housing 342 andshell 344, generally has a “d” or “b” shape, depending on which side isviewed. Herein, this shape will sometimes be referred to herein as a“d/b shape,” or by similar terms. The term “d/b shape” is intended to beapplicable, even though the actual shape, in FIGS. 17 and 18, includes acurved portion 344 a depending downwardly of an end of a straight sideportion. In spite of this, the overall shape is reminiscent of a “d” or“b,” and thus the terms are used.

More specifically, and referring to FIG. 18, the shell section 415engages curved or round rounded end section 344 a, tangentially. This isnot the case for shell section 416, which provides for outwardly curvedsection 416 x in transition toward curved end section 344 a. Thisprovides the referenced “b” and/or “d” shape to the shell 402. Such ashape is useful, in general, when the dimension Y of the media pack 315,in FIG. 18 is smaller than the dimension X needed across region 380 toaccommodate optional safety cartridge 341, FIG. 13, or to provide to adesirable sized outlet 346, FIG. 17.

In general terms, herein, the dimension X references a dimension betweenoutlet end 317 of the media pack 315, and a closed end 344 a of theshell 344 (or filter cartridge housing 342). The dimension Y is ageneral dimension through the media pack 315 in a direction both:orthogonal to a general air flow direction therethrough; and, throughindividual layers or strips of media within the media pack.

Herein, the dimension “Z” is used to refer a distance between oppositesides 415, 416 of the filter cartridge 342 (or shell 344). Typically,the dimension Z will be approximately the same as the dimension Y.

In a typical application, the dimension X is at least 50% of each of thedimensions Y and Z; usually at least 75% and often at least 90%. In manyinstances, the dimension X will equal to or greater than the dimensionsY and Z; thus, often the ratios X/Y or X/Z will be at least 1.0, usuallyeach ratio (X/Y and X/Z) is within the range of 1.0-1.7, inclusive;typically 1.0-1.5, inclusive.

Attention is now directed to FIG. 19, a sectional view of cartridge 340,taken generally along line 19-19, FIG. 15. The cross-sectional view ofcartridge 340, FIG. 19, is generally analogous to the cross-sectionalview of FIG. 12.

In FIG. 19, then, internally secured media pack 315, with inlet face 316and outlet face 317 is viewable, secured within the filter cartridgehousing 342. The inlet face 316 is shown aligned with inlet face 345 ofthe cartridge 340. Clean air region 380 is viewable, defined under shell344 in particular by shell end section 344 a. Opposite end pieces 350,351 are shown molded-in-place. End piece 350 defines aperture 346, inseal arrangement 460. The seal arrangement 460 is supported by sealsupport ring 461, to form an inwardly directed radial seal. This seal issized and configured to form a seal to, and around, an outer surface 470o of flange 470 in the housing, FIG. 12.

Still referring to FIG. 19, end piece 351 is closed, with: outer sealperimeter 364, handle 363 and projection 366, with recess 367 projectingaxially away from outlet 346

Attention is now directed to FIG. 20, a schematic, cross-sectional viewtaken generally in the direction of line 20-20, FIG. 19. Here, thecross-sectional view is taken through the housing 342, and thus sections415, 416 can be directly examined, as well projection 416 x adjacent endsection 344 a, of shell 344.

In FIG. 21, an enlarged, side elevational view of safety cartridge 341,FIG. 12 is provided. The cartridge 341, FIG. 21, includes media 341extending between end pieces 375, 376. End piece 375 includes an outersurface 375 y with seal region 355 thereon, which will form a seal whenpushed into an interior surface of flange 470, FIG. 12. End region 376includes projection 377 thereon, which is sized to be engaged by, andsupported by, support 366 in cartridge 350.

B. A Second Example Embodiment from U.S. 61/003,215, FIGS. 22-31

The reference 500, FIG. 22, depicts a second embodiment of an aircleaner assembly according to the present disclosure. The air cleanerassembly 500 includes a pre-cleaner 501 and a main air cleaner assembly502.

In FIG. 22, the air cleaner assembly 500 is depicted in an orientationas would be typical for use. However it is noted in the principlesdescribed could be applied with an air cleaner assembly in a differentorientation, for example on its side.

Referring to FIG. 22, the pre-cleaner 501 includes a housing 505defining an inlet end 506, and a dust ejector outlet 507. The dustejector outlet 507 in the example depicted is not oriented directeddownwardly, and thus would typically be attached to a vacuum dustscavenge system for drawing collected dust out of the pre-cleanerassembly 501.

Still referring to FIG. 22, the pre-cleaner 501 includes a plurality ofcyclonic separator tubes 508. The tubes may be as conventional for usein pre-cleaner assemblies. Air would typically enter the assembly 500 inthe direction of arrow 510. This would direct the air into inlet end 506of the pre-cleaner 501. In particular the air would enter the cyclonictubes 508, and the pre-cleaner 501. Cyclonic tubes 508 would separateout a portion of the dust, which would exit pre-cleaner 501 throughoutlet 507. The air, after passage through the optional pre-cleaner,would then move into the main air cleaner assembly 502 in the generaldirection of arrow 511. Within the main air cleaner assembly 502, theair is passed through a main filter cartridge, with filtering. Air isthen optionally passed through a secondary or safety filter cartridge.The filtered air is generally directed outwardly from the main aircleaner assembly 502 through outlet 515.

In general terms, the main air cleaner assembly 502 includes a housing516. For the examples shown, the housing 516 is provided with a mountingpad arrangement 518, by which the air cleaner assembly 500 could bemounted in a vehicle or other equipment.

Still referring to FIG. 22, the view oriented is generally a top (inlet)and an outlet side, as a perspective view.

Attention is now directed to FIG. 23, a second top perspective view ofthe assembly 500. Here the view is taken toward a side 520 opposite theoutlet 515. In particular, the view is taken toward side 520 whichincludes a removable service or access cover 521 thereon.

Thus, access cover 521 is removable to allow service access to aninternally received filter cartridge.

The access cover 521 is shown with a handle receiver 525 therein. Thehandle receiver 525 includes a recess on the inside surface of theaccess cover 520, for receiving, projecting therein, a handle member ofa internally received filter cartridge, in use.

Attention is now directed to FIG. 24, a bottom plan view of assembly500. Again, pre-cleaner 501 is viewable mounted on main air cleaner 502,and in particular on an inlet end 519 of the housing 516. Outlet 515 isviewable, for filtered air exit from the air cleaner assembly 500.

Attention is now directed to FIG. 25, exploded perspective view of theair cleaner assembly 500, FIGS. 22-24. The view of FIG. 25 is generallyanalogous in orientation, to the view of FIG. 23. It can be seen thatpre-cleaner 501 comprises a shell 505 generally mountable over inlet 519of housing 516. It is noted that for the particular housing 516depicted, the inlet 519 is oriented so that air flow therethrough, isgenerally orthogonal the outlet flow through outlet 515.

Referring to FIG. 25, air cleaner housing 516 generally defines interior516 i, in which is received at least a main filter cartridge assembly540, and in some instances an optional safety cartridge assembly 541,through access opening 516 o. For the particular assembly depicted,access cover 521 is shown.

The access cover 521 is shown with an upper end 544 having a pluralityof apertures 545 therethrough. The apertures 545 are aligned to positionover the projections 546, along upper edge 516 x housing 516. Thus, theaccess cover 521 can be hung by the engagement between projections 546and receivers 544. Latching closed can then be accomplished with latchmember 550.

Main filter cartridge 540 is a service part, i.e., cartridge 540 isconfigured to be removed from assembly 500 and be replaced, or berefurbished, in due course. In particular, the main filter cartridge 540includes a filter media therein, which would become loaded withcontaminant, in time. Sufficiently loaded, the cartridge 540 is removedand is either refurbished or is replaced. Typically it is replaced witha new, but analogous, filter cartridge 540.

Still referring to FIG. 25, in general, main filter cartridge 540includes a media pack therein, indicated generally at 630 having aninlet flow face 631 and an opposite outlet flow face 632. The media pack630 may be, in general, analogous to media pack 515, as previouslydiscussed.

Referring still to FIG. 25, the cartridge 540 includes an inlet end 555.The inlet end 555 is a side of cartridge 540 into which inlet air isdirected, for filtering. Positioned within cartridge 540, to receiveinlet air through inlet 555 is the filter media pack 630, discussedbelow. The media pack would typically be permanently (i.e.non-removably) secured within an outer main filter cartridge housing 600of cartridge 540, discussed below.

Still referring to FIG. 25, the main filter cartridge 540 includes aperimeter housing seal member 557 around a closed side 558 thereof,positioned to seal against interior 516 i the housing 516, wheninstalled, adjacent air cleaner access opening 516 o. Compression of theaccess cover 521 against edge 557 x of the seal member 557 willfacilitate this. This is discussed further below.

Attention is now directed to FIG. 26, a second top perspective explodedview of the assembly 500, in this instance the orientation generallycorresponding to that of FIG. 22. FIG. 26, cartridge 540 is viewablewith inlet end 555. Also, outlet 560 for filtered air from filtercartridge 540 is depicted. It can be seen that within the example filtercartridge 540 the air enters through end 555 and exits through a secondlocation 560 generally orthogonal to the entrance. This is discussedfurther below.

Also viewable in FIG. 26, is optional secondary or safety cartridge 541comprising media 565 extending between opposite end caps 566, 567. Inthe example depicted, end cap 566 is closed, i.e. it includes noaperture therethrough. End cap 567, however, is open and defines anopening 568 therethrough, in gas flow communication with an interior 565i surrounded by media 565. The end cap 567 includes an outer perimeter569 configured to form a housing seal arrangement 570, positioned toengage a portion of the housing 516 and seal there against, in use, asdiscussed below.

Analogously and as discussed below, aperture 560 in the main filtercartridge 540 is an interior surface 573 configured to define a housingseal 575. The seal 575 is configured to engage and seal against portionof the housing 516, in use.

In a typical operation, air will enter filter cartridge 540 in thegeneral direction of arrow 580. Within the cartridge 540, the air willpass through, and be filtered by a media pack 630 using media of thetype previously discussed, and generally as shown and discussed below.Filtered air will then exit the main filter element 540 through theaperture 560. When the main cartridge 540 is installed within thehousing 516, and when optional cartridge 541 is present, the cartridge541 will generally project into an interior 540 i of the main cartridge540 at a location downstream from media pack 630. When this is the case,before the air exits aperture 560, it passes through media 565 into openinterior 565 i. Then, as the air passes outwardly through aperture 560it also passes through aperture 568, to leave housing 516 through outlet515.

Still referring to FIG. 26, recess 525 r defined by projection 525, FIG.23, is viewable. The recess 525 r is sized and shaped to receiveprojecting therein a filter cartridge handle member 590, not viewable inFIG. 26. The handle member 590 is viewable in FIG. 25.

Attention is now directed to FIG. 27. In FIG. 27, cartridge 540 isviewable. The cartridge 540 generally comprises a main filter cartridgehousing 600 having a sidewall 601 defined by a shell 602. Shell 602defines an open end 603 corresponding to open end 555 of cartridge 540and to inlet face 631 of media pack 630. Housing 600 includes first andsecond end members 605, 606. In FIG. 27, end member 606 can be viewed ashaving optional handle member 550 thereon. End member 606 also includesperipheral housing seal member 610 thereon.

The shell 602 generally has first and second, opposite, sides 615, 616and a closed end section 617. In FIG. 27, media pack 630 isschematically depicted within housing 600, i.e. shell 602. The mediapack 630 is depicted within an inlet flow face 631 and an oppositeoutlet flow face 632. Typically, the media pack 630 will be adhesivelysecured, and typically sealed, to opposite side sections 615, 616 ofshell 602, along edges 615 a, 616 a, respectively. Thus, the media pack630 is typically non-removably secured within filter cartridge housing600.

Attention is now directed to FIG. 28. Here cartridge 540 is againviewable, the view being taken generally toward end 605 of housing 600.The end 605 can be a molded-in-place member. The end 605 can comprise,for example, a molded-in-place foamed polyurethane member.

Referring to FIG. 28, end 605 is viewed as having therein, aperture 560defining interior surface 573 with housing seal arrangement 575 thereon.Interior 540 i of main cartridge 540 is designated. At region 670, aclean air region within interior 540 i is designated. The clean airregion 670 is generally oriented between inlet flow face 632 of media630, and shell 602, in particular closed end 617 of shell 602.

Attention is now directed to FIG. 29, an end elevational view takentoward end member 605, FIG. 28. By examination of FIG. 29, it can beseen that shell member 602, defined by opposite side pieces 615, 616 andclosed end 617, for the example shown, generally defines a “u”-shape.The media pack 630 is positioned between opposite side sections 615,615, typically secured thereto with a adhesive, for example a sealant.End member 605 can be a molded-in-place end member, closing a side endof the media pack and a side of the end shell 602, but for passage ofaperture 560 therethrough, into clean air region 670.

Dimensions X, Y and Z can be as generally previously defined, for thepreviously described embodiments.

In FIG. 30, a side elevational view of cartridge 540 is depicted. Theview be taken generally toward side 615 of shell 602. Dimension X,extending across clean air region 670 between outlet flow face 632 ofinteriorly received cartridge 630 and closed end 617 of shell 602 isshown, schematically.

Referring to FIG. 30, end member 606 is depicted having an internalprojection shown in phantom lines, at 690. Internal projection 690projects into clean air region 670, from a remainder of end member 606.The projection 690 can be molded into the end member 606, or cancomprise a preform made, and then put in place in end member 606, whenend member 606 is molded-in-place. End member 606 can comprise foamedpolyurethane, molded-in-place; and, projection 690 can comprise, in someinstances, a preform, for example, a plastic member embedded within aremainder member 606 when formed. The projection 690, generallycomprises a secondary cartridge support member, and will engage, FIG.26, end 566 secondary cartridge 541, during installation, to support end566. This can be conducted, for example, by projection 690 extendingaround end 566, or by projection 590 being sized to project into arecess formed in end 566.

In general terms, side member 605, FIG. 30 will be referred to as “open”due to aperture 560 extending therethrough as a filter cartridge outletflow aperture. On the other hand, end member 606 will be generally becharacterized as a “closed” member, as it has no apertures therethrough.

When end members 605, 606 are molded-in-place, they would typicallyinclude embedded therein, respectively, opposite sides 630 a, 630 b ofmedia pack 630. Thus, end members 605, 605 seal closed sides 630 a, 630b of media pack 630.

Still referring to FIG. 30, peripheral seal member 610 includes an outerend surface 610 x. When the access cover 521, FIG. 26, is pushed inplace, surface 610 is engaged and will compress, bulging region 610radially, outwardly, in the general direction shown at arrow 695. Thiswill facilitate sealing against inner surface 516 i; of housing 516,FIG. 25, in a manner analogous to that previously discussed for apreviously described embodiment.

In FIG. 31, a view taken toward end member 606 is depicted.

Assembly cartridge 540, for example, would be analogous to that ofcartridge 340, as follows. Media pack 630 would be preformed. Shell 602would be provided in the selected shape, for example u-shape, and mediapack 630 would be positioned between side sections 615, 616, typicallysealed thereto with an adhesive. There resulting combination would thenbe used in a molding process, to form opposite side member 605, 606.Either one of the side members 605, 606 could be formed first.

A usable foamed polyurethane, for molded-in-place portions of members605, 606 (and analogous members in the previously described embodiment)can comprise a material formed with as molded density of not greaterthan 30 lbs/cu.ft. (0.46 g/cc), typically not greater than 15 lbs/cu.ft(0.24 g/cc), and sometimes no greater than 10 lbs/cu.ft (0.16 g/cc). Theoverall resulting material would typically be formed with a hardness,shore A, of no greater than 30, typically no greater than 25 and oftenwithin the range of 12-20. It is noted that in some applicationsalternate densities and hardnesses can be used. However, the rangesstated will be typical, for many applications.

IV. An Improved Embodiment, FIGS. 32-65

The reference numeral 700, FIG. 32 generally designates an improved aircleaner assembly according to the present disclosure. The air cleanerassembly 700 generally comprises a housing 701. The housing 701includes: first and second, opposite, sides 702, 703; an access coverend 704; and, an opposite, not viewable in FIG. 32, outlet end 705. Thehousing surface includes a inlet (top) end 706, normally directedgenerally upwardly when housing 700 is installed; and, a closed (bottom)end opposite inlet end 706, the closed end generally being indicated at707. Typically, the closed end 707 will be directed downwardly orsubstantially downwardly in installation.

Still referring to FIG. 32, it is noted that the particular air cleanerassembly 700, depicted does not include a precleaner positioned overinlet end 706. In some applications and techniques described withrespect to air cleaner assembly 700, a precleaner can be used. Theprecleaner can be in accord with the precleaner previously discussedherein, although alternatives are possible.

As will be understood from further drawings and description below, theair cleaner assembly 700 can be in general accord with air cleanerassemblies previously described herein.

Still referring to FIG. 32, access cover end 704 is typically providedwith a removable access cover 710 thereon that, when removed, providesfor service access to an interior of housing 701. The particular accesscover 710 depicted, is secured in place by a latch arrangement, in theexample depicted comprising a plurality of latches 711, althoughalternatives are possible. Also, the particular access cover 710depicted, is completely removable from a remainder of housing 701,during servicing, although alternatives are possible.

Still referring to FIG. 32, it is noted that when oriented with inlet706 depicted upwardly and opposite closed end 707 directed downwardly,when viewed from the side, the housing 701 generally has a b/d-shape,(or b/d-shaped). For the particular example housing 701 depicted, whenviewed from the access cover end 704, the shape is generally a“d-shape.” Of course alternative shapes, including, for example,u-shapes, are possible.

Attention is now directed to FIG. 33, in which a side elevational viewof air cleaner assembly 700 is taken at an end opposite that viewable inFIG. 32. Thus, in FIG. 33, the view is taken toward outlet end 705.Being directed toward an end opposite from FIG. 32, for the particularexample assembly 700 depicted, the end view of FIG. 33 shows a generally“b-shape” for the housing 701.

In FIG. 33, some example dimensions are provided as follows: AA=164.4mm; AB=116.1 mm; AC=350 mm; AD=61 mm; and, AE=200 mm.

It is noted that throughout the description of the embodiment of FIGS.32-65, some example dimensions will be provided, corresponding to theunit depicted. It is also noted that alternate dimensions andconfigurations could be used with the principles described herein.

Still referring to FIG. 33, outlet end 705 includes an air flow outlet720 thereat, for filtered air to leave air cleaner assembly 700, and tobe directed to downstream equipment, such as, eventually, an air intakefor an internal combustion engine.

Comparing FIGS. 32 and 33, it can be seen that bottom end 707 includes acentral lower projection 707 p thereon. It will be understood fromfurther description below, that the central projection 707 p generallyextends across housing 701 between ends 704, 705, and provides a lowertrough in the housing 701. Comparing FIGS. 32 and 33, it can be seenthat it is reasonable to characterize the housing shape as a“d/b-shape”, in spite of the presence of the of the projection 707 p;and the term “d/b-shape” and variants thereof, as used herein, is meantto include within its scope a configuration such as that shown in FIGS.32 and 33.

In FIG. 34, a side elevational view of air cleaner assembly 700 isprovided, the view being taken generally toward side 703, with portionsof side 703 being broken away to depict internal detail.

Referring to FIG. 34, mounting pad arrangement 725 usable for mountingthe air cleaner assembly 700 in position in equipment with which itused, is shown. Typically, housing 701 will be a molded plasticcomponent, and thus strengthening ribs 726 are shown in the housing 701.

Still referring to FIG. 34, at top inlet end 706 is provided air flowinlet 730, for air to be filtered entering housing 701. As previouslyindicated, air cleaner assembly 700 is depicted with no precleanerassociated therewith. If a precleaner were used, it would typically bepositioned over air flow inlet 730, analogously to previously describedembodiments.

Referring to the internal detail depicted in FIG. 34, frame member 732over interior portion of outlet 720 is viewable. A portion of internallypositioned main air filter cartridge 735 is also viewable, as is aportion of internally received safety filter cartridge 736.

In general terms, frame member 732 projects inwardly to housing 700,from outlet 720. Frame member 732 comprises a plurality spaced support732 a, tapering at narrow end 732 b, in extension from outlet 720inwardly of housing 701. Frame member 732 can assist in centering theopen end of a safety element 736 or a main filter cartridge 735 insertedinto air cleaner housing 701 through end 704, when access cover 710 isremoved.

In FIG. 34, some example dimensions are indicated as follows: BA=513.7mm; BB=350 mm; BC=299.9 mm; BD=25 mm; BE=415.9 mm; BF=114.3 mm; BG=40mm; BH=225 mm; BI=450 mm; and, BJ=639.2 mm.

Attention is now directed to FIG. 35, a view of air cleaner assembly 700taken generally toward top, inlet, end 706.

Referring to FIG. 35, the view is generally taken through inlet 730 toan interior 701 i of housing 701. The view is schematic and at inlet endfeatures for an internally received filter cartridge 735 are notdetailed, inside inlet 730. However, the reference numeral 735 is usedto indicate the general location of the internally received filtercartridge.

Attention is now directed to FIG. 36, a bottom plan view of air cleanerassembly 700; the view of FIG. 36 generally be taken from a directionopposite of that of FIG. 35. Referring to FIG. 36, it is noted thathousing 701 includes a bottom section 739, comprising projection 707 pwith a drain aperture arrangement 740 therein. For the particularexample housing 701 depicted, the drain aperture arrangement 740comprises first and second spaced drain apertures 741, although analternate number of drain apertures and location of drain apertures canbe used.

In general, the drain aperture arrangement 740 comprises one or moredrain apertures 741 through bottom 739 of housing 701. Should watercollect within an interior 701 i of housing 701, it will generally draintoward projection 707 p, along an interior of bottom 739, and outwardlythrough drain aperture arrangement 740. The apertures 741 depicted, arepositioned at approximate opposite ends of bottom 739 so that if thehousing 701 is slanted toward one side or other, of the sides 704, 705,the water will still drain.

In FIG. 37, a second view analogous to FIG. 34 is provided, free ofdimension lines for easier inspection. Features previously identifiedare indicated by the same reference numerals.

In FIG. 38, air cleaner assembly 700 is depicted in a top perspectiveview, generally directed toward access end 704. Features previouslyidentified are indicated by like reference numerals.

In FIG. 39, a schematic exploded perspective view of air cleanerassembly 700 is taken, generally toward upper inlet 706 and toward andalso toward access end 704. Individual componentry depicted in FIG. 39includes housing 701 (indicated as a remainder of the housing minus theaccess cover 710); access cover 710; main filter cartridge 735; andsafety or secondary filter cartridge 736.

In FIG. 40, a cross-sectional view of air cleaner assembly 700 isdepicted.

Referring to FIG. 40, as in previously described embodiments, mainfilter cartridge 735 can be seen to comprise a cartridge housing 744including a media pack 745 having an inlet flow face or end 746 and anopposite flow face outlet end 747. In general, the cartridge housing 744comprises: opposite end members 748, 749; and, outer shell 750. Ingeneral, the cartridge housing 744 defines an interior volume 744 i inwhich the media pack 745 is positioned; and, the outlet end interiorspace 751 sized and positioned to receive safety cartridge 736projecting therein. This is analogous to previously describedembodiments. (The media pack 745 can be a stacked, blocked, media packas previously described).

Referring to FIG. 40, example dimensions are indicated as follows:CA=513.7 mm; CB=350 mm; CC=299.9 m; CD=25 mm; CE=415.9 mm; CF=114.3 mm;CG=40 mm; CH=225 mm; CI=450; and, CJ=639.2 mm.

Still referring to FIG. 40, in general, air to be filtered will bedirected into inlet face 746 of media pack 745. The media pack 745 can,in general, comprise a stacked media pack of z-filter strips, aspreviously described. The air will be filtered as it flow through flutesextending between faces 746, 747, since the flutes (media pack) will besealed appropriately to cause the air to need to pass through the media,to exit outlet flow face 747. The air exiting outlet flow face 747, willthen be directed into an interior 736 i of safety cartridge 736, bypassage through media 755 of secondary or safety cartridge 736. The airis then directed in the general direction of arrow 759 outwardly throughcartridge housing outlet 760 and through air cleaner housing outlet 720.It is noted that this air flow direction is also through support member732.

As indicated, outlet flow from air cleaner assembly 700, also involvesoutlet flow though outlet end 760 of the cartridge housing 744 of mainfilter cartridge 735; and, through outlet end 761 of secondary or safetycartridge 736. These features will be described further below.

Still referring to FIG. 40, it is noted that when access cover 710 isremoved, by release of latches 711, closed end 749 of main filtercartridge 735 will be viewable. By grasping handle member 765, cartridge735 can be removed from interior 701 i of housing 701. This will leavesafety cartridge 736 in place, during servicing, if desired. Of coursesafety cartridge 736 can also be removed from housing 701 if desired.

It is noted that cover 710 includes a handle recess 765 r therein, forprojection therein of cartridge handle 765.

Still referring to FIG. 40, it is noted that when access cover 704 isremoved, housing 701 defines an outlet end 767, which provides a serviceaccess end for installation or removal of cartridge 735 and secondarycartridge 736. It is also noted that, as discussed below, at closed end749, main filter cartridge 735 includes a peripheral seal member 770which, under compression from access cover 710, by latches 711, willpress against housing access cover 710 and housing end 767, forming aseal thereat, inhibiting air and outer leakage to housing interior 701i, during use.

In FIG. 40, a housing seal flange 705, or flange arrangement, in housing701, in particular in end 705, for sealing cartridges 735, 736 thereto,is viewable in cross-section.

Such features were previously described herein, for an earlier describedembodiment.

Attention is now directed to FIG. 41, a cross-sectional view takengenerally along line 41-41, FIG. 40. It is noted that in FIG. 41, across-sectional line indicating the cross-section of FIG. 40, (i.e. line40-40) is depicted.

Referring to FIG. 41, shell 750 of housing 744 of main filter cartridge735 is viewable. Shell 750 (and thus housing 744) can be seen to haveopposite sides 775, 776, and a curved or arcuate end 777. (The end 777will be considered arcuate, even if it comprises short straight sectionsarranged in an arc). Further shell 775 defines an open access end 778opposite curved end 777, allowing for air flow entry into inlet face 746of media pack 745. The curved end 777 can be seen to be arcuate, and tohave a bottom 777 b and upwardly curved opposite sides or side portions777 c.

Analogously to previously described embodiments, and referring to FIG.41, dimension D₆ generally corresponds to a dimension X across a closedend section 751 of the shell member 744, downstream from the media pack745. The dimension D₅ generally corresponds to a dimension Z between anopposite side section 775, 776 of the shell member 750, where the shellmember engages the media pack 745, thus it also corresponds to adimension Y through the media pack 745 in a direction perpendicular togas flow therethrough and also perpendicular to the strips of media.This was previously described arrangement, the dimension X(corresponding to D₆, FIG. 41) in a typical arrangement is at least 50%of a dimension D₅ (corresponding to dimensions Y or Z as previouslydescribed). Usually the ratio of X/Y or X/Z is at least 0.5, usually atleast 0.75, and typically at least 0.9. In typically arrangements X/Zwill be at least 1.0 and not greater than 1.7; and, usually an amountwithin the range of 1-1.5, although are alternatives are possible. Forthe particular example shell 750, FIG. 41, the dimension X/Z (i.e. D₆/D₅is approximately 1.3).

For the particular example shell 750 depicted, side 775 is generallytangential to curved end 777, however side 776 is not tangential tocurved end 777. This results in the “b-shape” or “d-shape” (i.e.d/b-shape or b/d-shape) to a side view of the shell 750; i.e. an end ofthe cartridge 735 or cartridge housing 744.

Still referring to FIG. 41, it is noted that in open region 751 of shell750, which is a clean air region downstream from outlet face 747 ofmedia pack 745, a portion of safety cartridge 736 is shown incross-section.

Also referring to FIG. 41, bottom end 739 in which drain arrangement740, FIG. 36 is depicted, can be seen as a lowermost, dropped, sectionor trough 707 p.

In FIG. 41, some example dimensions are provided as follows: DA=164.4mm; DB=116.1 mm; DC=350 mm; DD=61 mm; and, DE=200 mm.

Attention is now directed to FIG. 42, in which an end elevationaldepiction of main air filter cartridge 735 is depicted. The view of FIG.42 is generally toward closed end 749. Closed end 749 includes anovermold (molded-in-place) portion 775 and a pre-form closed portion776. The overmold portion 775 will typically be molded-in-place, forexample from a material such as a foamed polyurethane. When overmoldportion 775 is molded-in-place, in general it will seal a end of anenclosed media pack, and close an end of the shell, while securingpre-form end closure portion 776 in place. The polyurethane used forovermold portion 775 will generally comprise a foamed polyurethane aspreviously characterized herein for member 605, 606, of cartridge 540.

Still referring to FIG. 42, end member 749 includes an outwardlydirected handle portion 765 thereon, projecting outwardly toward theviewer in the view of FIG. 42. Further overmold portion 775 includeperipheral rim region 778, adjacent end 749.

General features of cartridge 735, FIG. 42, are as follows: thecartridge 735 includes a cartridge housing 744 having an inlet end 780,and an opposite (bottom) end 781, a first side 782, and a second,opposite, side 783. End 780 corresponds to an inlet into which air isdirected during entry into cartridge 735. Outlet flow from cartridge 735is through end member 748 opposite end member 749.

It is noted, referring to FIG. 42, that the main filter cartridge 735has a general shape, when viewed from an end, corresponding b/d (ord/b)-shape. It is noted alternate shapes, for example a u-shape, can beused.

Attention is now directed to FIG. 43, a view directed toward filtercartridge 735, and housing cartridge 744, from an end 748 opposite end749. End 748 includes a overmold (molded-in-place) portion 785. Theovermold portion 785 closes an end of the media pack 745 adjacentthereto, closes an end of the shell 750 adjacent thereto and definesoutlet flow aperture 760. In particular outlet flow aperture 760 issurrounded by seal member 790, which forms housing seal member oncartridge 735. The housing seal member 790, generally, forms a seal withhousing 701, around cartridge outlet flow aperture 760, when cartridge735 is properly installed in housing 701.

Referring to FIG. 43, the particular housing seal member 790 depicted,is configured to form an inwardly directed seal, against inwardlydirected radial seal surface 791 of portion 790. Further, surface 791does not simply define a circular perimeter, but rather a perimeter,seal surface shape that includes an arcuate section 791 c, on one side,with an opposite side 791 d including a central vertex 791 v opposite acenter of arcuate section 791 c and engaged with arcuate section 791 cby two, straight, tangential side sections 791, 791 b extending atapproximately right angles to one another, away from central vertex 791v.

This shape for seal surface 791, and region 790 generally comprising:one arcuate side and an opposite side having central vertex with twostraight sections engaging the arcuate side, provides for a relativelylarge outlet flow aperture 760, for escape of filtered air from interior735 i of cartridge 735.

Still referring to FIGS. 42 and 43, it is noted that side 782 extendsgenerally tangentially, with the curved bottom section 795 of thecartridge 735 (and hosing 744); and, the side 783 does not engage curvedbottom section 795 tangentially. Of course, alternate possibilities canbe used, including for example, a u-shape as discussed above.

Attention is now directed to FIG. 44, a top plan view of filtercartridge 735 of main cartridge housing 744. The view, then, isgenerally directed toward top end or inlet 781. Positioned within inletend 781, would be provided media pack 745, FIG. 40. In particular, thesurface viewable would be inlet flow face or inlet end 746 of media pack745; detailed features of media pack 745 not being drawn in theschematic of FIG. 44. Generally, the media pack 745 would comprisestrips of single facer material extending between, and with oppositesides sealed by, opposite end members 748, 749.

In FIG. 44, a portion of shell 750, for cartridge 735, is depicted,extending between end members 748, 749.

In FIG. 45, a bottom plan view of cartridge 735 and main cartridgehousing 744 is shown. Here, a portion of shell 750 is also seenextending between end members 748, 749. The portion of shell member 750generally corresponds to a curved bottom 795, adjacent bottom 781 ofcartridge 735.

Still referring to FIG. 45, it is noted that curved bottom 795 includesan aperture arrangement 796 therethrough, the aperture arrangement 796depicted comprising apertures 796. It is noted that aperture arrangement796 comprises a first arrangement 796 a positioned generally adjacent,to and spaced from, end member 748; and, a second arrangement 796 bpositioned adjacent to, and spaced from, end 749.

In general, the aperture arrangement 796 is configured to allow drainageof water that may collect within an interior of shell 750, outwardlytherefrom. It is noted that the apertures 796 extend through shell 750at an interior region corresponding to a clean air region of cartridge735, downstream of media pack 745.

Still referring to FIG. 45, it is noted that each of the arrangements796 a and 796 b includes a bottom most aperture, aperture 796 x, 796 yrespectively; and, each of arrangements 795 a, 795 b includes additionalapertures 795 c positioned in portions (i.e. curved side portions 777 c,FIG. 41) of shell 750 curved upwardly from bottom 795. The additionalapertures 795 c provide ensures that drainage will occur, even if thecartridge 735 is tilted from an actual vertical orientation, FIGS. 42and 43. The bottom central apertures 796 x, 796 y will ensure thedrainage occurs when the cartridge 735 is oriented vertically as shownin FIGS. 42 and 43. Positioning aperture arrangements adjacent, butspaced from, opposite end member 748, 749, ensures that drainage willoccur even if the cartridge 735 is tipped downwardly toward end 748, ortipped downwardly toward end 749.

In FIG. 46, a side elevational view of cartridge 735 is provided. Aportion of shell 750 can be seen extending between end members 748, 749.Apertures 796 c can be seen. The view of FIG. 46 is generally towardside 783, FIG. 43.

In FIG. 47, a side elevational view of cartridge 735 taken toward side782, i.e. the side opposite side 783, is viewed. Apertures 796 c areviewable.

In FIG. 48A, a cross-sectional view of cartridge 735 is viewable. Heremedia pack 745, having inlet end 746 and outlet end 747 is viewable,positioned within shell 750, of main filter cartridge 744, and extendingbetween sides 748, 749.

Referring to FIG. 48A, seal surface 791 can be seen to be tapered,having a central step or rib feature 791 r which will provide formaximum compression, when pushed over an outlet tube of housing 701. Italso noted that embedded within housing seal 790 is provided supportring 800. The support ring 800 will form a pressure backing, for sealsurface 791, when pushed around an outlet tube.

Still referring to FIG. 48A, it can be seen that member 748, comprisingovermold 785, can be continuous in forming section 804 closing end 745 xof media pack 745; and, housing seal portion 790, defining an outlet forclean air from interior 735 i of cartridge 735 (or interior 744 i ofcartridge housing 744).

Also referring to FIG. 48A, end member 749 can be seen to compriseovermold 775 defining outer perimeter seal 778 and handle member 765,while also securing in place preform 776.

Referring to FIG. 48A, attention is now directed to preform 776. Preform776 comprises a secondary support projection including an outer sidewall776 s (or inwardly projecting peripheral ring) projecting into interior735 i of cartridge 735, in particular into clean air volume 750 idefined by curved end 795 of shell 750. The central interior portion ofpreform 776 is a closed end of the support projection, directed towardthe air filter outlet 760, includes a central recess therein forming anaxially outwardly directed receiver 776 r surrounded by sidewall 776 sand directed away from outlet 780. The receiver 776 r is positioned toreceive, projecting therein, a projection portion on a safety orsecondary cartridge when installed within region 776 x, as discussedbelow.

In FIG. 48A, some example dimensions are provides as follows: EA=593.8mm; EB=533.8 mm; EC=175 mm; ED=86.9 mm.

Attention is now directed to FIG. 48B, an enlarged fragmentary view of aselected portion of FIG. 48A. Here, seal support ring 800 is shownembedded with region 790. It is also shown that support ring 800 engagesan end or side edge portion 750 e of shell 750, creating an axialbearing of ring 800 against shell 750, at ends thereof.

Attention is now directed to FIG. 49, a cross-sectional view ofcartridge 735, taken generally along line 49-49, FIG. 48A. Here outletflow aperture 760 is viewable, having a shape with a curved or arcuateside 791 c, and an opposite side with a central vertex 791 v, and(straight) side sections 791 a, 791 c. The sides 791 a, 791 c generallyengaging, tangentially, arcuate side 791 c. Alternately phrased, theview of FIG. 49 is of outlet aperture 760 from an interior 735 i ofcartridge 730.

Still referring to FIG. 49, shell 750 can be seen as having oppositesides corresponding to cartridge sides 782, 783; side 782 engagingcurved bottom 795 of shell 750 tangentially; and, side 783 non-engagingcurved bottom 795 tangentially, but extending generally parallel to side782. Again, alternate shapes are possible.

Still referring to FIG. 49, media pack 745 having inlet flow face or end746 and outlet flow face or end 747, opposite end 746, is viewablepositioned within interior 735 i of cartridge 735 (or interior 744 i ofmain cartridge housing 744). It is noted that adjacent surface 746, atregions indicating generally at 805, the media pack 745 would typicallybe potted to, or i.e. sealed to, sides 782, 783 of shell 750. Of courseat the opposite ends, the media pack 745 would generally be embeddedwithin molded-in-place portions of end members 748, 749.

Attention is now directed to FIG. 50, a side elevational view ofcartridge 735 generally directed toward end 748. Here, the cross-sectionline 48A-48A, for FIG. 48A is indicated.

In FIG. 50, example dimensions indicated are as follows: FA=137.5 mm;and, FB=377.5 mm.

FIG. 51, cartridge 735 is viewable in a perspective, generally towardside 749 and top or inlet end 780. Preform 776 is viewable withinovermold 775. The preform 776 can be seen to have an outwardly directedcone 810, which defines an interior receiver 776 r, FIG. 48A. Flange 811is provided extending toward handle 765 from projection 18. Flange 811generally provides for indexing during a manufacture step.

Still referring to FIG. 51, it is noted that handle member 765 is shownwith apertures 765 a therein.

Still referring to FIG. 51, shell 750 (and main cartridge housing 744)can be viewed as having opposite sides corresponding to sides 782, 783of cartridge 735, and lower curved section 795, corresponding to bottom781.

Attention is now directed to FIG. 52, a view of cartridge 735 takengenerally toward inlet 780 and outlet end 748. Outlet aperture 760 canbe seen in end member 748, allowing a view of portion of interior 735 i.Selected apertures of aperture arrangement 796 are also viewable inshell 750.

Referring to interior 735 i, media section 820 is shown positionedwithin interior 735 i, and in particular in shell 750 along an interior750 i thereof, in a position overlapping apertures 796 (A second,analogous, media strip would be positioned adjacent end 749). The media820 will close aperture 796 to flow of unfiltered air therethrough, intointerior 735 i, from an exterior environment. The media 820 can beviewed as a media patch, secured within interior 750 i of shell 750, atan appropriate location. The media patch 820 can be made from mediasimilar to that used for media pack 745, but typically not corrugated,fluted or folded. A single layer strip 821, for example, can be securedin place by sonic welding, hot melt adhesive or other means.

In FIG. 53, an enlarged fragmentary view of a portion of FIG. 50, isviewable allowing further inspection of media 820 in the form of strip821.

Referring back to FIG. 52, it is noted that the outlet shape for outlet760, having curved side 791 c, and vertex 791 v, with sides 791 a, 791 bextending therefrom at right angles, is viewable. Also viewable in FIG.52 is recess 830, positioned in side 781 a directed toward end 780.Recess 830 provides a notch relating to indexing the support ring 800.

In FIG. 54, an exploded view of cartridge 735 is viewable. Media pack745 can be seen having inlet face 746 opposite outlet face 747 and sideend 785 x, 785 y which are embedded and molded-in-place pieces 748, 749,respectively, for sealing. It is also noted that the media pack 745includes opposite side surfaces 745 a, 746 b, extending between sides745 x, 745 y, and end surfaces 746, 747. The sides 745 a, 745 b areengaged by the shell 750, when cartridge 735 is installed. Typically aspreviously discussed, a potting or sealing material is positionedbetween sides 745 a, 745 b, and shell 750, usually adjacent inlet face746, when media pack 745 is positioned in shell 750.

Still referring to FIG. 54, shell 750 can be seen to have sides 782,783, and curved bottom 795. The curved bottom 795 can be seen to havethe aperture arrangement 791 therethrough, covered, in an interiorsurface 750 i by media patch 820.

Still referring to FIG. 54, it can be seen that overmold 748 will securesupport ring 800 in place. End member 748 will also seal closed side 745x and an end 750 x of shell 750. Of course, end member 748 will provideseal member 790, and flow apertures 760. Also viewable in FIG. 54, ispreform 776, which will be positioned within end 750 y of shell 750before overmold 749 is positioned. Overmold 749 will close end 750 y ofshell 750, and seal closed end 745 y of media pack 745, once installed.

In FIG. 55, a side (end) elevational view of shell 750 is viewable.Example dimensions are provided in FIG. 55, as follows: GA=137.5 mm;GB=2.2 mm; GC=271.4 mm; and, GD=175.5 mm.

In FIG. 56, a side elevational view of shell 750 is provided. Thedimension GE indicated is 565.8 mm.

It is noted that typically shell member 750 will be manufactured fromcellulose fiber sheet material, metal or plastic, as previouslydescribed for other embodiments. However, a variety of alternatematerials can be used for the shell 750.

In FIG. 57, an outside perspective view of preform 776. It is noted thatadjacent outer edge 776 o, preform 776 includes outwardly directedradial projection 775 p. Projections 775 p are oriented to engage shell750, when preform 776 a is positioned in place, along those portions ofpreform 776 which engage the shell 750. Also provided are projections775 x, which are oriented to become embedded within the overmold 749,and to overlap the media pack 745.

In FIG. 58, a perspective view directed toward an inside of preform 776is provided.

In FIG. 59, a plan view of an exterior of preform 776 is provided.

In FIG. 60, a cross-sectional view taken along line 60-60, FIG. 59 isviewable. Here, recess 776 r is readily viewable.

Attention is now directed to FIG. 61, in which support ring 800 isdepicted in perspective view. The support ring 800 can be seen tocomprise a curved section 800 c, comprising a side opposite a vertex 800v. The support 800 also includes side sections 800 a, 800 b, extendingoutwardly from central vertex 800 b at approximate right angles, andgenerally engaging curved side 800 c tangentially. Thus, support 800 isconfigured to surround aperture 760, FIG. 43 and to provide support forseal 791, having a similar shape. It is noted that support ring 800includes an outer surface 800 o with a plurality of outwardly flanges840 thereon, which are positioned to overlap and abut shell 750.

In FIG. 62, a plan view of support 800 is depicted. In FIG. 62, theindicated dimensions are as follows: HA=38.2 mm; HB=48.5 mm radius;HC=38.2 mm; and, HD=86.6 mm radius.

In FIG. 63, a side elevational view of support 800 is depicted. In FIG.63, the indicated dimensions are as follows: IA=27 mm; IB=25 mm; and,IC=22 mm.

In FIG. 64, safety cartridge 736 is depicted. The cartridge 736comprises a media pack 850 extending between opposite ends 851, 852. End851 is generally formed from a hard, molded-in-place polymer, such as ahard polyurethane, with central outwardly directed, conical projection853. Projection 853 is sized to be received in and supported by receiver776 r, FIG. 60. This is shown for example in the cross-section of FIG.40. End cap 842 is typically molded-in-place from a polyurethane that issoft and compressible, for example analogous to that used for sealmember 750 Seal 852 includes an outer seal surface 855, configured toform a radial seal with housing 701 FIG. 40.

Comparing the safety filter 736, FIG. 64 and the main filter cartridge735, FIG. 43, it will be understood that the seal surface 855 of thesafety cartridge 736 is defined in a generally circular perimeter,whereas the seal surface 791 of the main filter cartridge 735 defines apattern previously described of a arcuate side 791 c and an oppositeside having a central vertex 791 v and side sections 791, 791 bextending outwardly therefrom. Thus, two seal surfaces 790, 855 cannotbe sealed, completely, along opposite sides of a single seal flange.Referring to FIG. 40, an assembly in cross-sectional view, attention isdirected to housing seal flange 858. In the particular cross-sectiondepicted, seal member 790 and seal member 855 are shown sealed atopposite sides of flange 858. In some portions, flange 858 would beexpected to have a circular portion for seal surface 855, and anon-circular portion for the central vertex and sides of seal 790.

Referring back to FIG. 64, it is noted that media pack 850 has generallya conical shape, decreasing in cross-sectional diameter from end member852 to end member 851. The media pack 850 will typically comprise mediapositioned between an inner support liner 860 and an outer support liner861. Mesh or expanded materials can be used for liners 860, 861.

In FIG. 65, cartridge 736 is shown in side elevational view, with aportion shown in cross-section. Here, members 860, 861 can be seen inopposite sides of the media 864. In FIG. 65, example dimensions areindicated as follows: JA=31 mm; JB=531.8 mm; JC=128 mm; and, JD=150.9mm.

It is noted that assembly in accord with FIGS. 32-65 can be providedwith some of the features characterized herein above, with respect topreviously described embodiments; and, the previously describedembodiments can be provided with some of the features characterizedherein of the embodiment of FIGS. 32-65. Further, terminology used indescribing various embodiments, for analogous features and operations,can be applied to the other embodiments depicted as well.

It is noted that there is no specific requirement that an assemblyinclude all of the features of assembly 700, or components thereof, inorder to obtain some benefit according to the present disclosure.

V. Some Concluding Comments

According to an aspect of the present disclosure, a first or main airfilter cartridge is provided, usable as a service part in an air cleanerassembly. The filter air filter cartridge generally includes a mediapack non-removably positioned (secured) within a filter cartridgehousing. Although alternatives are possible, media pack typicallycomprises a stack of media strips of media defining an inlet flow faceand an opposite outlet flow face. Such a media pack defines a pluralityof flutes extending in a direction generally between the inlet andoutlet flow faces; and, the media pack is closed (sealed) to passage ofunfiltered air there-through, without passage through media within themedia pack. The media pack includes first and second, opposite, sidesextending between the inlet and outlet flow faces. In a typicalarrangement, the media strips comprise a strip of fluted media securedto a strip of facing media.

The filter cartridge housing includes a shell member. The shell memberincludes the media pack secured therein, and includes a closed endportion defining a clean air volume adjacent the outlet flow face of themedia pack. Example shell members are described, each of which havefirst and second opposite side sections, and a closed end portion.Typically, the closed end section has a bottom and opposite curvedsides. In some examples, the shell member has a d/b-shape. In anotherexample the shell member has a u-shape.

The closed end portion or section of the shell member can include adrain aperture arrangement therein. Typically, a filter mediaarrangement will be positioned over the drain aperture arrangement, toensure that unfiltered air does not move into the clean air volumedefined in the closed end portion of the shell member. The drainaperture arrangement can include a first aperture arrangement positionedadjacent to and spaced from a first end or end member of the shellmember of filter cartridge; and, a second aperture arrangementpositioned adjacent to, and spaced from, a second end member of theshell member or filter cartridge. Typically, the closed end portion ofthe filter cartridge comprises a bottom portion with opposite curvedsides. The drain aperture arrangement would typically include at leastone aperture in the bottom portion, and in an example described herein,at least one aperture in at each one of the opposite, curved, sides ofthe closed end portion.

The filter cartridge housing includes a first end member positionedalong the media pack first side, enclosing a side of the shell member.Typically, the first end member is molded-in-place and includes a firstside of the media pack embedded therein, and sealed thereby.

The first end member includes an air flow outlet arrangementtherethrough, in communication with a cartridge clean air volume definedbetween the outlet flow face of the media pack and the closed end of theshell member. Typically, the first end member is molded-in-place andincludes a first side of the media pack embedded therein, and sealedthereby.

The second end member extends along the media pack second side and aside of the shell member opposite the first end member. The second endmember is typically closed to passage of air therethrough. Typically,the second end member is molded-in-place, with the second side of themedia pack embedded therein and sealed thereby.

In a typical arrangement, the first end member of the air filtercartridge housing includes a first air cleaner housing seal arrangementthereon, oriented surrounding the flow outlet arrangement. An examplehousing seal arrangement comprises an inwardly directed radial seal. Anexample inwardly directed radial seal is described and depicted, whichincludes a seal support therein. In a typical arrangement, the first endmember is a molded-in-place end member, with the first air cleanerhousing seal arrangement molded integral therewith. In an example, thefirst end member comprises foamed polyurethane molded-in-place with aseal support ring embedded therein, surrounding the housing sealarrangement.

The inwardly directed radial seal or radial seal surface of the housingseal arrangement can define a generally circular perimeter. In analternate example described herein, a seal surface shape or perimeter isdefined which as one arcuate side and a second side with a centralvertex, having two opposite side sections extending therefrom.

In examples described, the air filter cartridge housing second endmember also includes a peripheral housing seal member thereon. Theperipheral housing seal member is oriented to engage, and to sealagainst, a portion of an air cleaner housing, when the air filtercartridge is installed for use. The second end member can comprise amolded-in-place end member, for example a polyurethane foam member.

In one example, the molded-in-place second end member includes asecondary filter cartridge support projection extending into the cleanair volume. In a specific example described, the projection has agenerally circular outer periphery and a closed inner end, the inner endincluding central axially outwardly directed recess therein. The recessis oriented to engage and support an end of a secondary filtercartridge, when the air filter cartridge is installed in an air cleanerassembly (for use), which also includes a secondary filter cartridge.

In another example, the projection of the second end member includes aninwardly projected peripheral ring sized and shaped to engage andsupport a safety or secondary filter cartridge.

In an example described, the secondary filter cartridge supportprojection comprises a preform piece, i.e. piece formed separately, andthen secured to second end member by being molded-in-place.

In example arrangements depicted, the closed end section of the shellmember is generally arcuate. The closed end section of the shell memberdefines a filter cartridge clean air volume having a dimension Xthereacross, from the media pack outlet flow face to the closed endsection of the shell, corresponding to at least 50% of a dimension Ythrough the media pack in a direction perpendicular to gas flowthere-through and perpendicular to the strips of media. Alternatelystated the dimension X in a typical arrangement is at least 50% of adimension Z between opposite side sections of the shell member.Typically the dimension Y and dimension Z are approximately the same.

Usually a ratio of X/Y or X/Z is at least 0.5, usually at least 0.75;and, typically at least 0.9. In typical arrangements the ratio X/Z willbe at least 1.0 and not greater than 1.7, usually an amount within therange of 1-1.5, although alternatives are possible.

In a typical arrangement, the media pack is blocked, stacked, mediapack, although alternatives are possible. Also typically a shell memberis selected from the group consisting essentially of: cellulose fibersheet (board) material; plastic; and, metal, although alternatives arepossible.

The second end member of the filter cartridge housing can be providedwith an outer surface having a handle projection thereon, to facilitategrasping of the filter cartridge.

There is no specific requirement that an air filter cartridge includeall of the features characterized herein, in order to obtain somebenefit in accord with the present disclosure.

In a second characterization of a first or main air filter cartridgeaccording to the present disclosure, a media pack is again non-removablysecured within a filter cartridge housing comprising a shell memberhaving first and second opposite side sections and a first closed endsection. Although alternatives are possible, the media pack typicallycomprises a stack of strips as previously described and is non-removablysecured within the shell member at a position between the first andsecond side sections; and, the shell member defines a clean air volumebetween the shell member closed end section and the media pack, the airclean air volume having a dimension X thereacross responding to at least50% of a dimension Z between the shell member first and second oppositeside sections. Typically the dimension X is as previously characterized,relative to the dimension Z.

In this second characterization, the filter cartridge housing includes afirst end member closing a first side of the media pack and the shellmember. The first end member includes an air flow aperture therethroughin flow communication with the clean air volume; and, the first endmember defines a housing outlet seal member thereon, around the air flowaperture.

In this second characterization, the filter cartridge housing includes asecond end member mounted opposite the first end member and closing thesecond side of the media pack and shell member. The second end member istypically closed to air flow therethrough.

Arrangements according to the second characterization can includevarious features and modifications as discussed above.

Also according to the present disclosure an air cleaner assembly isprovided. The air cleaner assembly generally comprises a housing havinga side wall defining an interior and including: an air flow inlet side;and, an air flow outlet arrangement. In an example depicted, the airflow outlet arrangement is oriented in the housing side wall to providean outlet flow direction generally orthogonal to an air flow inletdirection. The housing includes an access opening with a removableaccess cover thereover, along a side of the housing side wall oppositethe air flow outlet arrangement.

In an example air cleaner assembly described herein, the air cleanerassembly housing includes a bottom with a drain arrangementtherethrough, for water collected within the housing during use.

A removable and replaceable first air filter cartridge is positioned inthe housing interior. The first air filter cartridge can be generallyconfigured as previously described, and is sized to pass through theaccess opening, when the access cover is removed. The first air filtercartridge is oriented with: an inlet flow face of the media packoriented toward an air flow inlet side of the air cleaner housing; theair flow outlet arrangement of the first end member of the filtercartridge directed toward, and in air flow alignment with, the air flowoutlet arrangement of the air cleaner housing; and, the second endmember of the first air filter cartridge directed toward the accesscover of the air cleaner housing.

In a typical arrangement, a secondary filter cartridge that is separablefrom each of the air cleaner housing and the first air filter cartridgeis provided. The secondary filter cartridge can comprise mediasurrounding an open air volume. The secondary filter cartridge isremovably mounted on the air clean air housing over the housing air flowoutlet arrangement and projecting through the first end member of thefirst filter cartridge into the first air filter cartridge cleanervolume.

The secondary filter cartridge typically has a closed end remote fromthe air flow outlet arrangement. The second end member of the firstfilter cartridge can include an internal projection thereon insupporting engagement with a closed end of the secondary filtercartridge.

In an example arrangement described, the closed end of the secondaryfilter cartridge includes the central axial projection directed toward aclosed member of the first filter cartridge, when installed. The closedend member of the first filter cartridge includes a recess therein sizedand shaped to receive the central axial projection on the closed end ofthe secondary filter cartridge projecting therein.

Several example secondary filter cartridges are described. In one, agenerally conical shape is provided, with a larger, open, end engagingthe fluid flow arrangement of the air cleaner housing. In a second, agenerally cylindrical shape is shown, with an open end engaging theoutlet arrangement of the air cleaner housing.

In a typical arrangement, the air flow outlet arrangement of the aircleaner housing is surrounded by a seal flange having an inner surfaceand an outer surface. The first end member of the first filter cartridgeincludes a housing seal member surrounding the air flow outletarrangement therein, the housing seal member of the first air filtercartridge being removably sealed to the outer surface of the sealflange. Typically the secondary filter cartridge includes an open endwith an outer surface having a seal member thereon, which is removablysealed to the inner surface of the housing seal flange.

In an example arrangement described, the first air filter cartridgeincludes a peripheral housing perimeter seal member on the second endmember. The first air filter cartridge is positioned within the cleanerhousing with the peripheral housing perimeter seal member sealed to theair cleaner housing at a location adjacent to the housing accessopening. The sealing can be accomplished, for example, by forming aperipheral housing perimeter seal member from a soft compressiblemolded-in-place material, such as a foamed polyurethane, and compressingthe peripheral seal member with an access cover of the air cleanerhousing, causing the seal member to bulge outwardly to engage thehousing seal surface.

In an example arrangement described, the first air filter cartridgeincludes a handle member thereon, positioned on the second end memberand projecting in a direction away from the first end member. Thehousing access cover includes a handle member recess thereon, into whichthe handle member on the first air filter cartridge projects.

In an arrangement described herein, the filter housing outlet apertureincludes a projection arrangement extending into the housing therefrom.The projection arrangement can be used as a guide, for positioning themain filter cartridge and safety filter cartridge, during installation.

Also according to the present disclosure, methods of formation of an airfilter cartridge and use are described. The methods of formationgenerally involve attaching a shell member as previously described to amedia pack as previously described, typically by securing the media packnon-removably to the shell member, for example with a an adhesiveextending therebetween. First and second end members are positioned overopen ends of the shell member, to form the filter cartridge. Either oneof the two end members can be positioned first.

The shell member is generally chosen to define a clean air volumebetween a closed end thereof, across, and spaced from, the outlet flowface of the media pack. The clean air volume can be sized as previouslydescribed.

When the first end member is secured in position, it is configured withan air flow aperture therethrough, in communication with the clean airvolume. The first end member may be molded-in-place and include a moldedintegral housing seal member thereon, surrounding the outlet flowarrangement.

The second end member is typically closed, and may include a peripheralhousing seal arrangement thereon. The second member may further includea handle member thereon, projecting in a direction away from the firstend member.

A method of use of the filter cartridge, generally involves installingthe filter cartridge in an air cleaner housing as previously described;and, directing air to be filtered into the air cleaner housing throughthe housing inlet, and through the media pack of the filter cartridge.The air will then exit the media pack and enter the clean air volume ofthe filter cartridge. It is then turned and directed outwardly throughthe air flow outlet arrangement in the first end member. In someinstances, the method may be practiced with a secondary filter cartridgeprojecting into the clean air volume of the first clean air filtercartridge, as previously discussed.

There is no specific requirement that an air cleaner assembly,components thereof, methods of assembly or use include all of thedetailed features described herein in order to obtain some benefit tothe present disclosure.

What is claimed is:
 1. An air filter cartridge comprising: (a) a mediapack closed to passage of unfiltered air through the media pack, withoutpassage through media therein; (i) the media pack comprising a stack ofstrips of media defining an inlet flow face and an opposite outlet flowface; (A) the media pack defining a plurality of flutes extending in adirection generally between the inlet and outlet flow faces; and, (B)the media pack having first and second, opposite, media pack sidesextending between the inlet flow face and outlet flow face; and, (c) afirst end member non-removably secured to the media pack adjacent thefirst side of the media pack and having a portion extending in adirection away from the outlet flow face; the portion extending awayfrom the outlet flow face having a filter cartridge outlet flowarrangement therethrough; (i) the outlet flow arrangement comprising anair flow aperture in the first end member open to flow therethrough in adirection extending generally perpendicularly to a direction ofextension of the flutes; and, (ii) the first end member including afirst housing seal arrangement thereon, surrounding the air flowaperture.
 2. An air filter cartridge according to claim 1 wherein: (a)the first housing seal arrangement comprises a radially directed housingseal arrangement.
 3. An air filter cartridge according to claim 2wherein: (a) the first housing seal arrangement comprises a radiallyinwardly directed housing seal arrangement.
 4. An air filter cartridgeaccording to claim 3 wherein: (a) the first housing seal arrangementcomprises a seal surface defining: a first, arcuate, side; and, a secondside, opposite the first arcuate side, having a central vertex andopposite side sections.
 5. An air filter cartridge according to claim 1wherein: (a) the first housing seal arrangement comprises a seal surfacedefining: a first, arcuate, side; and, a second side, opposite the firstarcuate side, having a central vertex and opposite side sections.
 6. Anair filter cartridge according to claim 3 wherein: (a) the first housingseal arrangement has a non-circular shape with: at least one straightsection; and, at least one arcuate section.
 7. An air filter cartridgeaccording to claim 1 wherein: (a) the first housing seal arrangement hasa non-circular shape with: at least one straight section; and, at leastone arcuate section.
 8. An air filter cartridge according to claim 1wherein: (a) the first end member is molded-in-place on the first sideof the media pack.
 9. An air filter cartridge according to claim 8including: (a) a second end member non-removably secured to the mediapack adjacent the media pack second side and opposite the first endmember.
 10. An air filter cartridge according to claim 1 including: (a)a second end member non-removably secured to the media pack adjacent thesecond media pack side and opposite the first end member.
 11. An airfilter cartridge comprising: (a) an air filter cartridge housing; and,(b) a media pack non-removably secured within the filter cartridgehousing; (i) the media pack comprising a stack of strips of mediadefining an inlet flow face and an opposite outlet flow face; (A) themedia pack defining a plurality of flutes extending in a directiongenerally between the inlet and outlet flow faces; and, (B) the mediapack having first and second, opposite, sides extending between theinlet flow face and outlet flow face; and, (c) the filter cartridgehousing including: (i) a shell member defining a filter cartridge cleanair volume adjacent an outlet flow face of the media pack; (ii) a firstend member extending along a media pack first side and having a filtercartridge air flow outlet arrangement therethrough, in communicationwith the filter cartridge clean air volume; and, (iii) a non-circularseal member positioned on the first end member and surrounding the airflow outlet arrangement.
 12. An air filter cartridge according to claim11 wherein: (a) the non-circular seal member comprises a radiallydirected housing seal arrangement.
 13. An air filter cartridge accordingto claim 12 wherein: (a) the non-circular seal member comprises aradially inwardly directed housing seal arrangement.
 14. An air filtercartridge according to claim 13 wherein: (a) the non-circular sealmember comprises a seal surface defining: a first, arcuate, side; and, asecond side, opposite the first arcuate side, having a central vertexand opposite side sections.
 15. An air filter cartridge according toclaim 13 wherein: (a) the non-circular seal member has a shape with: atleast one straight section; and, at least one arcuate section.
 16. Anair filter cartridge according to claim 11 wherein: (a) the non-circularseal member has a shape with: at least one straight section; and, atleast one arcuate section.
 17. An air filter cartridge according toclaim 11 wherein: (a) the first end member is molded-in-place on thefirst side of the media pack.
 18. An air filter cartridge according toclaim 17 including: (a) a second end member non-removably secured to themedia pack adjacent the second side and opposite the first end member.19. An air filter cartridge comprising: (a) an air filter cartridgehousing; and, (b) a media pack non-removably secured within the filtercartridge housing; (i) the media pack being closed to passage ofunfiltered air through the media pack, without passage through mediatherein; and, (c) the filter cartridge housing including: (i) a shellmember defining a filter cartridge clean air volume adjacent an outletflow face of the media pack; (ii) a first end member extending along amedia pack first side and having a filter cartridge air flow outletarrangement therethrough, in communication with the filter cartridgeclean air volume; and, (d) a first housing seal arrangement surroundingthe air flow outlet arrangement; (i) the first housing seal arrangementcomprising an inner surface of the outlet arrangement configured toreleasably seal to a surface, of a housing, that is surrounded by theinner surface, during sealing; (ii) the first housing seal surfacedefining a non-circular inner perimeter shape with: two, straight,tangential side sections extending at right angles to one another and, aportion that defines a circular inner perimeter extending over at leasta half-circle.
 20. An air filter cartridge according to claim 19wherein: (a) the seal surface defines an inner perimeter with a centralvertex and an arcuate side opposite the central vertex, with the twostraight sections being on opposite sides of the central vertex andengaging the arcuate side; the arcuate side opposite the central vertexbeing the portion that defines a circular inner perimeter extending overat least a half-circle.